手動圧着工具 HT302 型 Manual crimping tools Type HT302 - Digi-Key
Contents
1. Do not handle the wires more than is necessary When touching the contacts wear appropriate gloves to avoid corrosion causing contamination Do not place any object on the contacts or drop it Avoid tangling of the terminated wires Should the wires become tangled handle the contacts with extreme care to avoid any deformation Do not handle contacts in the lance or contact areas Any deformation in these areas will affect performance Do not entangle the contacts with each other Store the terminated wires in a non corrosive environment Configuration of the tool 230 Date of manufacture Tool number Stationary handle2. 8 HS 2E ESO Hoan HERE The crimp height is in the specified range The bellmouth has an is correct size The protrusion of the conductor is correct The outer insulation is inserted in the conductor barrel The outer insulation is correct crimped in the insulation barrel The conductor does not protrude from the wire barrel The contact section of the contact is not deformed The lance is not deformed The wire barrel has no noticeable burr The finished crimped section is free from any material crack or rough surface on the outside of the barrel 6 9 e The bend angle in the contact is as specified in 8 Table of crimping conditions crimping quality standard Contact section of contact Q Bellmouth Protrusion of conductor 4X5 Position of outer insulation 9 Burr
3. 1 2 1 3 4
4. Tie at sufficient distance from the connector to assure that there are no forces applied to the inserted contacts 2 8 2 Connector continuity check When performing this test make sure that the tied wires do not interfere with the mating with the corresponding part Do not insert any test probes or other pins into the socket contact as it may damage it causing electric discontinuities 2 8 3 Handling of the contacts 900 GOQ O O
5. 5 i IJJI Ba 122 2 0E 076 D Wire barrel U shaped section of the contact which is compressed around the conductors with a mechanical force Configuration and dimensions after the completion are critical for maintaining mechanical and electri conductor crimp section cal performance of the contact 2 Insulation barrel U shaped section of the contact which is compressed around the outer insulation of the wire Its func tion is to act as a strain relief preventing transmission of any pull force on the wire to the conductor crimp section G m Retains the contact in the applicable insulator socket Any deformation of lance may prevent re tention or extraction of the
6. 2010 CAUTION No part of this manual may be reproduced without the written permission of Hirose Electric Co Ltd Descriptions in this manual are subject to change without notice We assume no liability to any claim for loss or failure to earn profit resulting from the use of the machine We assume no responsibility for any damage resulting from the improper use of the tools including failure to follow the instructions given in this Instruction Manual This includes repair or modification conducted by any third party other than Hirose Electric Co Ltd The specifications of the product are subject to change without notice HIROSE ELECTRIC CO LTD 2010 FS T 141 8587 5 5 23 T 222 8566 7 3 13 TEL 045 414 1406 045 402 7861 http www hirose co jp VS io Wor S Q HIROSE ELECTRIC CO
7. Correct stripping length After crimping the conductors should protrude from the top end of the Wire barrel and the Insulation barrel should be around the Outer insulation as shown on the illustration on the left Before crimping do not pull on the outer insulation or attempt to insert it in the Wire barrel 2 2 2 Stripped wire condition a Stripping length x Do not damage any BRORS WEHEN SDL E D Conductor should be free from any dam AES YAN TER age or partially broken missing strands X Incorrect stripping bat TEOR 2 The conductor and outer insulation cut a ium off s must be straight The outer insulation can not be loose 2 3 Bellmouth flare Bellmouth flare
8. FOR SAFE OPERATION The operators of the tool and the maintenance personnel who are in charge of maintenance and repair work are required to read the following SAFETY INSTRUCTIONS Fully understand and follow the descriptions given in this Instruction Manual and the warning symbols attached to the tool SAFETY INSTRUCTIONS Basic safety instructions Be sure to read understand and follow all the instructions and other materials supplied with the tool before use Save this Instruction Manual and make it available when necessary Safe operation Be sure to use the tool as instructed so that your fingers nor part of clothing is caught in the tool during crimping operation 1 This tool shall only be used for its originally intended purpose while following the instructions specified in this Instruction Manual Hirose assumes no responsibility for any misuse of the tool other than the intended use 2 Modifications to this tool is prohibited We assume no responsibility for accidents resulting from modifications Maintenance 1 To prevent possible accidents caused by unfamiliarity with the operation of the tool repair and adjustment of the tool shall be conducted only by fully trained maintenance personnel Any repair and adjustment beyond the range covered by the instructions
9. 1 Handling precautions The tools can not be adjusted for crimp height or configuration Only specified wire size construction and type must be used with the applicable contact and tool Do not crimp other than the specified contact or wire Do not subject the tool to physical impact or drop Do not attempt to release the moveable handle before completing full compression as this may damage the tool Handle will re lease after completion of the full compression The handle can not be opened before automatic release of the ratchet 2600 oM Do not apply excessive compression on the handles after full compression Occasionally the moveable handle may remain closed after the full compression Insert a flat blade screwdriver or similar tool as shown on illustration above to re
10. Maintenance and inspection Routine maintenance D Upon completion of work wipe the tool with a soft cloth to remove any stains or foreign particles specially in the crimper and anvil areas 2 Close the handles making sure that the crimper and anvil slide smooth without any interference Store in the dry place Routine maintenance HRS offers maintenance service to evaluate condition and performance of the tool Request this service from the place of purchase or the nearest HRS representative Repair of the tools Contact the place of purchase or nearest HRS representative Describe exact nature of the problem Do not diss assembly the tool If instructed ship the tool in a secure package with a written description of the problem HRS does not sell individual components for the tools Depending on it s condition in some cases the tool may NOT be repairable 1 2 Basic outline of crimp operation General description of the crimp process 2 1 Configuration and function of crimp contact 2 1 1 Configuration of crimp contact Contact section
11. Caused by damage or wear of the crimp sections of the tool Can cause deformation of the contact cracks or peels of the material large or irregular crimping burr Burr Caused by damage or wear of the crimp sections of the tool Can cause deformation of the contact cracks or peels of the material degradation of the electrical connection or loss of the wire retention 6 2 7 Insertion of contact into housing 2 7 1 Checking the lance height lt Lance height must be as specified on applicable drawing 50 tJ lt AR 2 2 7 2 Assembling procedure example
12. 180 1 2 3 Withdraw the releasing Withdraw the crimper in the direction shown by the arrow Rotate the crimper 180 and re insert in the tool showing the marking of the applicable wire gage used Re insert the releasing pin Caution Some crimpers used in this tool may be non rotating Replacement procedure will not require rotating 180 7 Crimping conditions and crimping quality standard 1 NR 2a po 1 2 1 Check to be sure that the contact that has been crimped using the tool satisfies the standerd described in 8 Table of crimping conditions and crimping qual
13. Caused by incorrect stripping of the wire or it s positioning in the crimping section of the tool Can cause failure of the connec tion or interfere with the insertion of the terminated contact in the corresponding insulator socket 6 Loose strands of the conductor Loose Caused by the loose conductor in the wire Can cause erratic electrical connection and loss of wire retention in the crimp sections of the contact Deformed contact Bent UP DOWN UP DOWN be caused by the wear of the tool positioning of the contacts in the crimping sections of the tool or handling of the contact Excessive angle will prevent insertion o
14. Cop The lance was deformed and did not engage in the rectangular opening 2 7 4 Contact extraction Contact extraction procedure varies with a specific connector insulator housing Specific extraction tools are listed in applicable catalogs 2 7 5 Verification of the complete contact insertion 1 uin direction 2 1 Verify visually that the lance is fully engaged in the rectangular opening 2 Apply slight pull force on the wire in the direction shown on the illustration and verify that the contact can not be pulled out 7 8 Other precautions 2 8 1 Precautions when tying the wire
15. Deformed insulation barrel Kickback Kickback Caused by the use of incorrect wire or contact Excessive protrusion may expose part of the contact after insertion in the corresponding insulator housing and may cause electrical shorts Uneven anvil indentation Uneven anvil indentation Even anvil indentation Good product Caused by the wear of the anvil side of the tool Can cause degradation of the electrical connection 2 Damage or nicks on the crimp s outer surfaces Damage or nick
16. 2 3 1 Hold the terminated wire within 10cm of the end of the crimped contact nC 2 Orient the contact lance as shown on illustration on the left and align it with the housing 7O C m 3 Insert it until the lance is fully engaged confirmed with an audible sound 2 7 3 Checking the assembly condition of the housing Good The lance is properly engaged in the rectangular opening in the housing 25 Z The contact is moving in direction of the arrow float as illustrated Inadequate insertion Partial insertion Lance is not engaged in the rectangular opening Inadequate insertion 2224
17. Testing method of tensile strength 20 mm 80 mm Secure the crimped contact on applicable fixture assuring that the wire can be freely pulled and the force can be measured Apply pull at the rate of 20 to 80 mm per minute until the failure of the crimp section wire pulled out The value of the pull out force must be higher than the minimum specified 2 6 Confrmation of the shape of contact after crimping 2 6 1 Standards for acceptable crimp 8 See 8 Table of crimping conditions and crimping quality standard for the specified values
18. Crimp height is critical factor in determining the correct crimp condition and must be as specified Specified wire size construction and style must be used The crimp height requirement may not be applicable with some wires although they may be within the specified dimensions Use the micrometer for measuring the crimp height Crimp height outer insulation Micrometer anvil Crimp height conductor Micrometer spindle Measure near the center of the barrel 2 5 Tensile strength of crimped section and measuring method 2 5 1 Tensile strength of crimped section Retention strength of the crimped wire when the pull force N is applied to it The pull force is defined for each style of the con tact 2 5 2
19. Serial number 110 AWG No Marking of applicable wire P p a 7 i Carrier cutter E S uw Ss Moving handle 4 58 h ET i RR E Dix n hom bc ics s gt S Anvil Crimper 1 7 7 Cable stopper i 2 2 Release pin AWG No Marking of applicable wire AWG No IMarking of applicable contact Crimper 4 Table of tools No Standard applicable wire for tool Tool number HRS Applicable contact HRS STYLE AWG No mm HRS tool No No Applicable HRS No Sectional area mm Outside diameter of contact No the outer insulation 1 DFISG TB2630HC 550 0O256 1 DF13 25630SCF 536 0300 5 UL1571 26 30 0 055 0 145 0 65 9 1 0 2 DF14 2688 CR HT 550 026 1 1 DF14 2628S8CF 538 0001 7 UL1571 26 28 0 089 0 141 0 54 1 0 31DF14 3032 CR HT I550 0262 4 DF14 G3032SCF 538 0003 2 UL1571 30 32 10 035 0 055 A4 HT302 DF19S 902 4539 7 J DF19 2830SCFA 685 000 1 2 UL1571 28 30 0 057
20. 4 standard me 13 2 6 2 Example of defective crimping asoooooooooeeeeeeeeeeee 5 8 Table of crimping conditions and crimping 2 7 Insertion of contact into housing 7 quality 14 2 7 1 Checking the lance height 7 1 Precautions in handling the tool and maintenance Tool B D Patblade
21. Bellmouth Conductor Outer insulation Wire barrel Serrations Insulation barrel Lance retention tab 2 1 2 Function of each part of crimping contact D U po NE
22. Bellmouth Bellmouth must be present at the rear of the conductor crimped section and must be within the specified dimensions Size of it varies with each contact style Absence of the bellmouth may cause conductor breakage and will affect the tensile strength of the crimp Excessive bellmouth may indicate insufficient tensile strength of the crimped section of the contact and af fect the electric connection 2 4 Crimp height 2 4 Crimp height
23. Lance Contact conductor section of crimp height Outer insulation section of crimp height Rough surface 2 6 2 Example of defective crimping D None or excessive bellmouth No bellmouth Excessive bellmouth 2 Insulation bulge or protrusion Conductor is invisible Caused by incorrect positioning of the contact in the crimping section of the tool Can cause conductor break low pull out force or electrical connection failure E Caused by incorrect stripping of the wire or it s positioning in the crimping section of the tool Conductor can be broken 3
24. Partial insertion of the conductor Conductor is invisible 1 4 Insufficient compression of the crimp sections Outer insulation is not visible E 5 Too long Caused by incorrect wire stripping Can cause conductor break low pull out force or electrical connection failure Caused by incorrect wire stripping Can cause conductor break low pull out force or electrical connection failure Too long protrusion of the conductor
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28. LTD 5 23 OSAKI 5 CHOME SHINAGAWA KU TOKYO 141 8587 JAPAN PHONE 81 03 3491 9741 FAX 81 03 3493 2933 http www hirose com 0 10 Printed in Japan
29. 0 089 0 50 DF19 3032SCFA685 0002 5 30 32 0037 0 057 0 60 DF19A 2830SCFA 685 0048 6 28 30 0 057 0 089 DF19A 3032SCFA 685 0046 0 30 32 0 037 0 057 5IHT302 DF20B 902 4540 6 DF20B 2830SCFA 686 0025 7 UL1571 28 30 0 057 0 089 28305 DF20F 2830SCFA 686 0042 6 28 30 0 057 0 089 5 Operating procedures 5 1 Crimping procedure TT N Lom Nc AUTION TO prevent injury do not place the fingers between the handles or crimping sections 1 HRS 2 3 10cm 1 Hold the tool with HRS logo and HRS tool number facing up 2 Compress the handle unti
30. ATAD PO112 2 Second edition HT302 Manual crimping tools Type HT302 INSTRUCTION MANUAL CAUTION Be sure to read this Instruction Manual carefully before using it to secure safe operation Save this Instruction Manual so that it is available whenever necessary HIROSE ELECTRIC CO LTD N VERA
31. f the contact in the corresponding insulator housing 5 Deformed contact Twist Twist be caused by the wear of the tool positioning of the contacts in the crimping sections of the tool or handling of the contact Excessive deformation of the contact will prevent insertion in the corre sponding insulator housing Deformed contact Rolling 2 Micrometer spindle 22 2 EE Micrometer anvil Can be caused by the wear of the tool positioning of the contacts in the crimping sections of the tool or handhng of the contact Excessive deformation of the contact will prevent insertion in the corre sponding insulator housing
32. given in this Instruction Manual is prohibited We assume no responsibility for accidents caused by improper repair or adjustment the use of non genuine part s To protect against personal injury assure that screws and nuts are properly tightened after the completion of repair adjustment works or replacement of the parts Periodical cleaning of the tool is recommended In the event that your tool fails to perform satisfactory after repair or adjusting immediately stop the work and contact HRS for service Forward Thank you for purchase of our manual crimping tool For safe operation read understand and follow this Instruction Manual 1 2 7 0 7 7 3 7 2 FERT ESSEN 18 EESSESEEEHEREESESENSSEERHRERRRREREEREREREEEEREERE e 2 7 4 im 08 MERE 7 2 1 2060 SAU 2 2 7 5 eset 7 2 1 1
33. ion NOTER 2 housing M 7 2 1 Configuration and function of crimp contact 2 2 7 4 cde CMM nene 7 2 1 1 Configuration of crimp contact 2 NEHIICRHOI OT TH edd 2 1 2 Function of each part of crimping contact 2 2 8 Other precautions oe troia iani o tod insi eoe eps 8 2 2 Stripping of wire outer insulation 3 2e 8 2 2 1 Correct stripping 1 3 8 2 2 2 Stripped wire 3 TI 8 2 3 Bellmouth flare ee 3 Configuration of the 1 9 2 4 Crimp e 3 4 Table of tools 10 2 5 Tensile strength of crimped section 5 Operating 10 measuring GIOS 4 B 2 5 1 Tensile strength of crimped section 4 5 1 Crimping procedure 5 10 2 5 2 Testing method of tensile strength 4 5 2 Removing carrier chips eeereeee 11 2 6 Confirmation of the shape of contact after 6 Replacing the crimper 12 crimping 00000000000000000000009000000000000000000000000000000000090090 4 7 Crimping conditions and crimping quality 2 6 1 Standards for acceptable
34. ity standard with respect to the crimp height and the tensile strength 2 Check to be sure that the contact that has been crimped using the tool is within the standard of good product with respect to the shape Caution 1 To use a wire a covering diameter of which is different from that of the standard wire please contact our Business Division or the distributor in your area 2 The figure below is an example of the shape of contact Use the figure for reference of configuration Covering position NS Bellmouth A Protrusion of the length TS DEN ABE L we Wire barrel section lt 7 i Wide Wire barrel S ak SN 59 4 en m Lance height A z gi if applicable ie 5 Qg Insulation barrel section Wide Insulation barrel L X c z x 1 80 290 Em VHOS058g eLO osgo XA vzo xvn xn xn zo go 9Omwewdl S gpo 720 0 0
35. l the moving handle releases and HRS tool number HRS HRS logo Release Contact guide is fully open 3 Place the contact on the anvil and insert it into the contact holder until it comes in contact with the stopper in the contact holder Caution The deformed contact cannot be passed Do not use it When the contact is passed there is a response Wire stop of click The position where there is a response of click when the contact comes on the anvil is the mer a Carrier cutter crimping position 4 Enlarged view of the crimping section 8 Contact E Wire stop Wire 4 Strip the covering of the cable by a given length Then match the cable to the position of co
36. lease it In addition applying an excessive compression can produce a play in the hand tool With the hand tool with a play the normal pressure cannot be obtained So be careful 6 Assure that the crimp condition after the termination with the wire is within specification B C
37. ntact guide Contact guide Setscrew 3 Pull out the contact guide following the direction of the ar TOW _ If carriers and carrier chips gather in the circled parts re move them After completion of removal of carriers and carrier chips assemble the manual crimping tool by reversing the disas sembly procedure Be sure to check the crimping quality after reassembly 6 Replacing the crimper o Crimp side of the tool can rotated as shown on the illustration below to fit the wire gage used Anvil side is stationary and can not be removed Release pin 180 Turn the crimper by 180 1 2 3
38. ntact while taking care Contact stopper not to allow contact wire to loosen Refer to 8 Table of E Carrier cutter crimping conditions and crimping quality standard for the stripping dimensions Caution Do not press the contact directly with the cable since Enlarged view of the crimping section there is a possibility of defective crimping o 6 7 8 8 Carrier AIEO Fon BE 5 Grab the handle by hand until the ratche
39. t is released Caution The carrier is cut at the same time of crimping Be careful that the cut carrier does not enter inside the tool When the operation is performed while foreign materials such as the carrier and thelike are inside the tool there is a possibility of tool breakage or defective crimping 6 Grab the handle by hand until the ratchet is released and the handle is opened 7 Draw out the crimped contact while holding the cable Caution Be careful not to allow the contact to hit against the cable stopper etc to deform 8 Verify the crimp correct dimensions refer to paragraph 8 Table of crimping conditions and crimping quality standard 5 2 Removing carrier chips Because of the structure of this manual crimping tool its hand tool is likely to be clogged with chips of the cut contact carrier If the crimp height suddenly varies check the manual crimping tool following the procedure described below 1 1 Loosen the screw which secures the co
40. terminated wire from the insulator body socket contact retention tab Note Some contacts may NOT have lance and be retained in their respective housings by other means 4 Bellmouth flare Critical configuration of the crimp section of the contact whose function 15 to avoid breakage of the ter minated conductor and assure strength of the crimp 5 Serrations Deformations or cross serrations of the material inside the wire barrel whose function is to break pos sible oxidation films on the contact and conductors during the crimping thus assuring stable electrical connection 6 Contact section Configuration of the contact which will make electrical and mechanical connection with the corre sponding mating contact 2 2 Stripping of wire outer insulation 2 2 1 A FUvZR amp R GCO BZS Correct stripping length Stripping length of the wire is specified for each contact Correct crimping depends on accurate stripping of the wire 7 E
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