DCF-S-0033-1(95.5) Japan Aviation Electronics Industry, Ltd. Connector - Number Division Spec: Page 19 Original issued: Feb. 14 , 2001 TITLE: Rev. Date DCN-No. Crimp Data for Series FI-C3-A1 / FI-XC3-1 / 2 Sep.18.2003 053322 FI-AC3-1 / FI-RC3-1A / FI-RC3-1B contacts 3 Nov.20.2003 053790 4 Jun.20.2005 057605 ISSUED: 2ND PRODUCTION Engineering Dept. Prepared Checked Approved Approved F.Kawano K.KOIDE A.IWASAKI Y.NOSE Prep Chkd Appd S.SHIMIZU A.IWASAKI S.SHIMIZU - A.IWASAKI T.OOKAWA S.SHIMIZU A.IWASAKI D.TSURUTA CAUTION Check that operation manual T703000-01E (applicator) is provided in addition to this manualIf not, contact us. Be sure to read T703000-01E before operation since all safety precautions are described in it. Properly keep this operation manual and T703000-01E near the applicator so that anyone can refer to them at anytime. Be sure to use the machine by following the instructions given in this operation manual and T703000-01E. Otherwise, we will not be responsible for any accidents that may result. Don't to repair or adjust, without the procedure specified with this operation manual, it cause is to brake the tool or product the rejected items. If you feel the tool abnormally or brake the tool, please inquire our shop or tool service, and repair it. JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, Number Connector Division - Page 29 1.Applicator Part description of the applicator used : 350-FI-2B (Applicable Press No.CP210-1BCP215-4B) 2. Part description of applicable contact and wire Applicable wire is stranded 7 annealed copper. conductors. Using not specified wire, please ask us whether the wire is usable or not. Contact part description Applicable wire Insulation diameter FI-C3-A1-15000 AWG#28 thru AWG#32 0.45 thru0.9mm FI-XC3-1-15000 AWG#30 thru AWG#36 0.45 thru0.75mm FI-AC3-1-15000 FI-RC3-1A-15000 FI-RC3-1B-15000 AWG#30 thru AWG#36 Less than0.5mm AWG#30 thru AWG#32 0.44 thru0.6mm Note :The crimper,anvil and crimp condition differ in each contact. For details,plaese refer to paragraph 4. 3.Allpicable wire , insulation diameter , and insulation stripped length 3-1.Applicable wire Vinyl insulated wire 3-2. Insulation stripped length Insulation stripped length: 1.3 thru 1.7mm Note :Please make sure that the insulation stripped length is within the above dimension. At the time , inspect if wire is not damaged , cut , or disheveled. If so , remove or remedy it. JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, - Number Connector Division Page 39 4.Crimp data by contact type 4-1.FI-C3-A1 4-1-1.Applicable crimper,anvil Insulation anvil Wire anvil Insulation crimper Wire crimper Part discription 725-03161-030 725-03200-031 725-03200-032 725-03200-033 Inscribed NO. 161-30 200-31 200-32 200-33 4-1-2.Applicable wire,crimp height,crimp tensile strength,Disk set mark Disk Set Wire Size Crimp Height Range Min.Crimp Tensile Mark (AWG) (mm Strength (N) C AWG#28 0.45 thur 0.50 13.1N D AWG#30 0.43 thur 0.48 9.8N E AWG#32 0.40 thur 0.45 5.8N 4-1-3Crimp height adjustment disc set mark, Insulation cam set mark and Insulation diameter Insulation Cam set Mark 13 4 5 6 7 8 Insulation Dia. 0.900.8 0.7 0.6 0.5 Insulation Support Height 1.05 0.95 0.85 0.75 Insulation Dia. 0.90.75 0.65 0.55 0.45 Insulation Support Height 1.05 0.95 0.85 0.75 Insulation Dia. 0.90.75 0.65 0.55 0.45 Insulation Support Height 1.00 0.90 0.80 0.70 Disc set Mark C D E Note: The figures shown in above table are not specified values, but for reference purposes only. JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, Page - Number Connector Division 49 4-2.FI-XC3-1,FI-AC-3-1,FI-RC3-1A&FI-RC3-1B 4-2-1. Applicable crimper,anvil Insulation anvil Wire anvil Insulation crimper Wire crimper Part discription 725-03249-030 725-03249-031 725-03249-032 725-03249-033 Inscribed NO. 249-30 249-31 249-32 249-33 4-2-2.Applicable wire,crimp height,crimp tensile strength,Disk set mark Disk Set Wire Size Crimp Height Range Min.Crimp Tensile Mark (AWG) (mm Strength (N) C AWG#30 0.40 thur 0.45 9.8N D AWG#32 0.375 thur 0.425 5.8N E AWG#36 0.35 thur 0.40 1.9N 4-2-3.Crimp height adjustment disc set mark, Insulation cam set mark and Insulation diameter FI-XC3-1 Insulation Cam set Mark Disc set Mark C D E 1 2 3 4 5 6 7 8 Insulation Dia. 0.75 0.7 0.6 0.5 Insulation Support Height 1.0 0.9 0.8 0.7 Insulation Dia. 0.65 0.55 0.45 Insulation Support Height 0.85 0.75 0.65 Insulation Dia. 0.55 0.45 Insulation Support Height 0.7 0.6 1 2 3 4 5 6 7 8 Insulation Dia. 0.5 Insulation Support Height 0.5 Insulation Dia. 0.45 Insulation Support Height 0.5 Insulation Dia. 0.45 Insulation Support Height 0.5 FI-AC3-1 Insulation Cam set Mark Disc set Mark C D E JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, - Number Connector Division Page 59 FI-RC3-1A & FI-RC3-1B Insulation Cam set Mark 3 4 Insulation diameter. 0.6 0.5 Insulation Support Height 0.85 0.75 12 57 Note1: Be sure to make the insulation hight under 0.53mm on FI-AC3. (Over 0.53mm is not acceptable due to the insulation diameter of housing. It is 0.54mm. ) Note2: The figures shown in above table are not specified values, but for reference purposes only. 5.Notes in operation 5-1 FI series contacts are so small in size, it may happen that a crimper strikes against an anvil and they become damaged when making crimping with a contact and wire being not installed. To maintain the quality, be sure to make crimping with a contact and wire being installed. 5-2 It is not easy to locate a wire with a wire stopper because the applicable wires this contact are very thin. It is recommended that a wire is put on the contact barrel in advance before making crimping. 5-3 This tool can use for FI-C3-A1, FI-XC3, FI-AC3, FI-RC3-1A and FI-RC3-1B by changing the crimper,anvil When this tool is delivered, the specified crimper,anvil has built in already. To purchase another crimper,anvil. please make sure the proper part number according to the assembly procedure of contact or following chart.. Crimper, anvil Contact FI-C3-A1 FI-XC3AC3-1 RC3-1ARC3-1B Insulation anvil Wire anvil Insulation crimper Wire crimper 725-03161-030 725-03200-031 725-03200-032 725-03200-033 725-03249-030 725-03249-031 725-03249-032 725-03249-033 JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, - Number Connector Division Page 69 6.Check of the crimped contact This paragraph provides criteria of discrimination of " Proper " crimped contact after crimping operation. For detail information about this ,please refer to manual JAHL. Proper Crimped Contact: " Proper crimped contact " is crimped as shown below. (1) Crimp height is satisfied with crimp standard.(refer to para.4) (2) Wire strands tip is extended from the wire barrel. (3) Wire insulation does not intrude into the wire barrel. (4) Wire strands do not protrude between the wire barrel and the insulation barrel. (5) Wire insulation is wrapped in the insulation barrel. (6) Bell-mouth(not crimped part)is formed. (7) Crimped surface is not got too rough. Bell-Mouth Insulation Crimp height Wire barrel Insulation barrel BLOWN-UP VIEW OF APPLICATOR JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, Number Connector Division JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. - Page 79 DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, - Number Connector Division PARTS LIST OF APPLICATOR INDEX NO. DESCRIPTION PARTS NO. QTY 1 Applicator body 743-03005-001 1 2 Base plate 722-03013-002 1 3 Left slide guide 722-03005-003 1 4 Right slide guide 722-03004-004 1 5 Contact feed plate 722-03005-005 1 6 Adjusting plate 743-03004-006 1 7 Fixed plate 743-03004-007 1 8 Adjusting screw 701-03004-008 1 9 Applicator set screw 750-03004-009 2 10 Feed lever 742-03005-010 1 11 Feed lever shaft 708-03005-011 1 12 Feed finger holder 734-03004-012 1 13 Feed finger 732-03004-013 1 14 Pivot bush 710-03005-014 2 15 Contact pressure plate 723-03005-015 1 16 Pin for feed 704-03005-016 1 18 Feed plate cover 722-03263-018 1 19 Pivot block 743-03004-019 1 20 Lift cam unit 700-03004-020 1 21 Key 723-03004-021 1 22 Roller pin 704-03004-022 1 23 Roller 711-03004-023 1 24 Feed actuating cam 741-03004-024 1 25 Crimper holder 743-03081-025 1 26 Screw for contact hold 701-03004-026 2 27 Spring pin for movable cutter 28 Front actuator unit 700-03092-028 1 29* Front movable cutter 726-03263-029 1 30 Insulation anvil Refer to para 4 1 31 Wire anvil 1 32 Insulation crimper 1 33 Wire crimper 1 34 Feed actuating lever 742-03004-034 1 17 1 35-01 Anvil block 743-03247-035-01 1 35-02 Anvil spacer 720-03263-035-02 1 36 Insulation spacer 711-03092-036 1 37 Feed spring bracket 744-03005-037 1 38 Twisted spring 762-03004-038 1 JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. Page 89 DCF-S-0033-2(95.5) Japan Aviation Electronics Industry, - Number Connector Division INDEX NO. DESCRIPTION PARTS NO. QYT 39 Wire stopper unit 700-03263-039 1 40 Feed adjusting shaft 708-03004-040 1 43 Feed spring 762-03004-043 1 44 Cutter spring 762-03004-044 1 45 Cutter block 743-03092-045 1 46 Positioner 724-03263-046 1 47 Set-screw for insulation cam 701-03004-047 1 48 Insulation cam unit 700-03004-048 1 49 Spring for insulation cam 762-03004-049 1 50 Crimp-height adjusting disk 715-03023-050 1 51 Contact pressure spring 762-03004-051 2 52 Crimp-height locating shaft 708-03004-052 1 53 Spacer 715-03132-053 1 54 Locating ball 765-03004-054 1 55 Spring for locating ball 762-03004-055 1 57 Locating pin for insulation cam 59 E-ring for feed adjusting shaft 754-03004-059 1 60 E-ring for cam shaft 754-03004-060 1 61 Pin for adjusting screw 62 Bolt for safety cover 701-03005-062 1 63 Safety cover 748-03005-063 1 64 Fastening screw for safety cover 701-03005-064 1 65 Collar 711-03005-065 1 68 Wire pressure 727-03247-068 1 69 Wire pressure spring 762-03247-069 1 101 Screw with hexagonal hole M4x4 7 102 2 103 Bolt with hexagonal hole M4x10 11 104 4 105 M8x20 1 106 M5x10 1 107 M3x4 1 108 M6x15 4 110 M4x30 or 35 2 116 Knock pin 5x20 2 117 6x15 2 118 Bolt with hexagonal hole M3x15 1 119 Cross head screw assembling washer M4x10 1 1 1 JAE Connector Div. Proprietary. Copyright(c) 2001, Japan Aviation Electronics Industry Ltd. Page 99