ELCO Engineering Specification INSTRUCTION FOR MINI-VARILOK HAND TOOL 1. CONTROLLED DOCUMENT RELEASED FROM ENGINEERING Date: 2003.01.13 11:06:29 Z SPECIFICATION DISTRIBUTION This is a company confidential document and should only be issued to specific users as detailed below. a) Final Inspection. b) Customer Requirements 2. ELCO TOOL PART NO. 06 7858 01 3. ELCO CONTACT 60 8216 0313 4. DESCRIPTION: Two Cavity Non-adjustable Hand Crimper 5. FEATURES This tool is designed to cover complete wire range (22-30AWG stranded wire) without adjustment, and has a positive action cycle controlled ratchet mechanism. The intended use covers field maintenance, small production and model shop or laboratory crimping requirements. 6. Tool Calibration & Crimp Tensile Assurance Although the only valid method of determining that tool is correctly adjusted and is performing properly is to: 1/ Perform pull test on crimped termination. (See min. tensile value chart). 2/ Take dimensional measurements from cavity of tool (see calibrating instructions). Calibration Instructions 1/ Crimp a piece of 0.06” diameter soft solder in either cavity and check height and width dimensions (see chart). 2/ Without contact in tool measure ratchet release pressure at a point 1.75” from handle end; the pressure required is 50-60lbs. CONTACT CAVITY CONDUCTOR CAVITY Height Width 0.032” to 0.036” 0.066” to 0.070” 0.026” to 0.030” 0.066” to 0.070” 22-24 26-30 Height Width ELCO EUROPE (A DIVISION OF AVX LTD.) CONFIDENTIAL PROPRIETARY THE DRAWING ON THIS PRINT AND INFORMATION THEREWITH ARE PROPRIETARY TO ELCO EUROPE (A DIVISION OF AVX LTD.) AND SHALL NOT BE USED OR DISCUSSED IN WHOLE OR IN PART WITHOUT ELCO EUROPE'S WRITTEN CONSENT. Compile Description Newmarket, Suffolk. MB Instruction Sheet 1 England. CB8 0BB. Copyright Elco Europe Size Specification Number Issue AV 90-2268-7131-00-000 ELCO EUROPE 101235 18-01-01 Page 1 Form 106-01-178 Issue 1 ELCO 7. Engineering Specification CRIMPING INSTRUCTIONS 1/ Place contact in desired crimp cavity (see marking on tool for wire gauge) and push to seat against contact stop. 2/ Close tool until second or third ratchet tooth is engaged. 3/ Insert pre-stripped wire 0.11” (+0.03/-0.00) strip length through contact to wire stop, making sure all strands remain in contact crimp area. 4/ Close handle until ratchet releases and tool opens. 5/ Remove crimped contact. WIRE SIZE 22AWG 24AWG 26AWG 28AWG 30AWG INSULATION DIA. 0.046min/0.054max 0.040min/0.048max 0.035min/0.043max 0.031min/0.039max 0.028min/0.036max MIN. TENSILE VALUES 15lb 10lb 5lb 3.5lb 1.5lb ALL DIMENSIONS ARE IN INCHES Compile Description Newmarket, Suffolk. MB Instruction Sheet 2 England. CB8 0BB. Copyright Elco Europe Size Specification Number Issue AV 90-2268-7131-00-000 ELCO EUROPE 101235 18-01-01 Page 1 Form 106-01-178 Issue 1