Page 1
D 101
ERG740 ERGONOMIC HAND TOOL
OPERATING INSTRUCTIONS
for RSK Series Wrap Around Connectors
IMPORTANT: Read and understand all of the instructions and safety information in this
manual before operating or servicing this tool.
INTENDED USE:
or multiple conductor shielded cables. It Is suggested that the customer evaluate the suitability
of these connectors and verify their performance for the particular application .
Wrap around connectors have been designed to ground the shield of single
WARNING
KEEP ALL BODY PARTS AWAY FROM DIE NEST
DURING GAGING OR CRIMPING PROCEDURE.
OPERATING INSTRUCTIONS
1
1.
Measure the diameter of the cable shield using a calibrated
measuring tool or the RSK gauge (part number RSK-LEHRE)
which is in the tool case lid. Rotate the cable in order to
locate the maximum shield diameter. Exert only light
pressure on the cable to get an accurate measurement, see
Figure. 1.
When using the RSK gauge , try to nd the appropriate slot
in the gauge by ensuring that the cable only goes in the top
of the slot. If the cable goes completely to the bottom of
the slot, you should try the cable in the smaller adjacent
slot.
Once you nd the appropriate slot, you can read the
associated RSK connector by the color of the slot and the
appropriate die by the number marked below the slot.
2. For twisted pair and other non-symmetrical shielded
cables, measure the dimension of the major axis or the
largest width of the cable.
When you use the RSK gauge, try to nd the appropriate
slot in the gauge by tting the largest width of the cable
into the slot. Similar to step 1, if the cable goes completely
to the bottom of the slot, try the next smaller adjacent slot.
3. Once the shield diameter is established, refer to Table 1 for
the appropriate connector and installing die.
MATCHING THE CONNECTOR AND DIE TO THE CABLE
HANDLES ARE NON-INSULATING.
DO NOT CRIMP ON HOT ENERGIZED WIRES.
DIAMETER OF SHIELD
(1.27 - 1.79 mm) .050 - .070 in.
(1.80 - 2.28 mm) .071 - .089 in.
(2.29 - 2.55 mm) .090 - .100 in.
(2.56 - 3.00 mm) .101 - .118 in.
(3.01 - 3.34 mm) .119 - .131 in.
(3.35 - 3.65 mm) .132 - .143 in.
(3.66 - 4.13 mm) .144 - .162 in.
(4.14 - 4.71 mm) .163 - .185 in.
(4.72 - 5.12 mm) .186 - .201 in.
(5.13 - 5.86 mm) .202 - .230 in.
(5.87 - 6.36 mm) .231 - .250 in.
(6.37 - 7.00 mm) .251 - .275 in.
(7.01 - 7.62 mm) .276 - .300 in.
WARNING
80
70
60
TABLE 1
CONNECTOR CAT.
NO. & CODE
RSK101 or
RSK5101
RED
RSK201 or
RSK5201
BLUE
RSK301 or
RSK5301
YELLOW
RSK401 or
RSK5401
GREEN
90
0
10
20
30
50
40
DIE CAT. NO
(STEEL)
D-101A
D-101B
D-201C
D-201D
D-201E
D-201F
D-301G
D-301H
D-301J
D-401K
D-401L
D-401M
D-401N
FIGURE 1
GROUND WIRE
RANGE
1 OR 2 PIECES 0.25mm
#24 AWG STR
OR 1
#22 AWG STR
1 OR 2 PIECES 0.25mm
#22 AWG STR
or 1 PIECE 0.5mm
#20 AWG STR
1 OR 2 PIECES 0.25mm
#22 AWG STR
1 PIECE 0.5mm OR 2
#20 AWG STR
1 OR 2 PIECES 0.5mm
#20 AWG STR
or 1 PIECE 0.75mm
#18 AWG STR
TA04632 B Page 1 of 2
Page 2
2
INSTALLING THE DIES IN THE
ERG740 TOOL
1. Open the tool handles completely
to fully retract the ram.
2. Insert the stem of upper die into
the tool frame.
3. Insert the separation spring of the
lower die into the upper die
opening. Push up rmly, and
insert the lower die stem into the
hole in the ram.
D 101 A
UPPER DIE STEM
UPPER DIE
SEPARATION
SPRING
NEST AREA
LOWER DIE
LOWER DIE STEM
RAM
4
GROUND WIRE PREPARATION
1. For a single ground wire. strip the wire 7/16 in (11mm) and
twist the strands together.
2. For two ground wires. strip each wire 1/2 in. (12mm) and twist
the two wires together.
3. If hairpinning (hooking) the ground wire is desired, strip the
wire 1/2 in . (12mm) and bend it as shown. Use one die size
larger.
CAUTION
Do not solder dip the ground wire ends.
Do not use solid ground wire.
3
CABLE PREPARATION
CAUTION
During all stripping operations, use extreme care to
prevent nicking or cutting of the shield or inner
conductor insulation. This could result in short circuits.
These connectors
NOTE:
should not be used with
multi-conductor shielded
cables whose conductors are
solid or stranded bonded wire.
1. Remove the cable jacket
as required and prepare
the shield as shown in the
standard method
illustration.
2. When the cable inner
conductor insulation is
vinyl of .015 in, or less
thickness or Teon* of
.010 in. or less thickness,
use foldback method 1 or
2 as ilIustrated.
3. When the shield is foil or is
spiral wrapped, use
foldback method 2.
4. When using either
foldback method, be sure
to measure the diameter
of the shield after it is
folded back. Refer to
Table 1 for proper die
selection.
*Teon is a registered
trademark of E.I. Du Pont De
Nemours and Company
SHIELD
JACKET
7/16 in. (11 mm)
STANDARD METHOD
7/16 in. (11 mm)
JACKET
FOLDBACK METHOD 1
JACKET
SHIELD ROLLED BACK
FOLDBACK METHOD 2
AS
REQ.
COND. DIELECTRIC
AS
REQ.
SHIELD
AS
REQ.
COND. DIELECTRIC
COND. DIELECTRIC
GROUND
WIRE
1/4 in. (6 mm)
NOTE: DO NOT FORM OR BEND
INSULATION
GROUND LEAD TRAP
HAIRPIN GROUND WIRE
5
1. Insert the connector, with the ground trap facing up, into the
nest area of the die. Be sure to center the connector.
2. Place the ground wire into the ground trap and the shielded
cable into the bottom to the connector. Be sure to butt the
cable jacket and the ground wire insulation against the metal
connector edge. The ground wire can exit from either direction.
3. Squeeze the tool handles completely to form the connector
around the shield.
INSTALLING THE CONNECTOR
ON SHIELDED CABLE
CAUTION
Be sure that neither the cable outer jacket nor the
ground wire insulation is under the metal portion of
the connector. This will overload the dies.
Dies
Ground Wire
Dies
Cable
D 101 A
Connector
GROUND TRAP
GROUND WIRE
GROUND TRAP
CABLE
For Parts or Service, contact the Thomas & Betts Tool Service Center at
WARRANTY: Thomas & Betts sells this product with the understanding that the user will
perform all necessary tests to determine the suitability of this product for the user's intended
application. Thomas & Betts warrants that this product will be free from defects in materials
and w orkmanship for t he per iod sta ted on the e nclosed warranty card. Upon prompt
notication of any warranted defect, Thomas & Betts will, at its option, repair or replace the
defective product or refund the purchase price. Proof of purchase is required. Misuse or
unauthorized modication of the product voids all warranties.
Limitati ons and Exclusi ons: THE ABOVE WARR ANTY IS THE SOLE WARRAN TY
CONCERNING THIS PRODUCT, AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS
OR IMPLIED , INCLUDING B UT NOT LIMITE D TO ANY IMPLIED WARRANTY OF
MERCHANTABIL ITY OR FITNESS FO R A PARTICU LAR PURPOSE, WH ICH ARE
SPECIFICALLY DISCLAIMED. LIABILITY FOR BREACH OF THE ABOVE WARRANTY IS
LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO
CIRCUMSTANCES WILL THOMAS & BETTS BE LIABLE FOR ANY INDIRECT, SPECIAL,
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
1-800-284-TOOL (8665).
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
6
GAUGING THE DIES
1. Install the die set into the
ERG740 Tool.
2. Close the tool handles until the
die faces are touching.
3. Using calipers, measure the die
nest height and compare to the
die gauging chart to ensure die
nest opening is within the
specied tolerance range.
CAT. No. DIM. (mm) TOL.
D-101A 3.6 mm ±0.10 mm
D-101B 3.9 mm ±0.10 mm
D-201C 4.4 mm ±0.10 mm
D-201D 4.6 mm ±0.10 mm
D-201E 4.9 mm ±0.10 mm
D-201F 5.1 mm ±0.10 mm
D-301G 6.2 mm ±0.10 mm
D-301H 6.5 mm ±0.10 mm
D-301J 6.8 mm ±0.10 mm
D-401K 8.0 mm ±0.10 mm
D-401L 8.2 mm ±0.10 mm
D-401M 8.8 mm ±0.10 mm
D-401N 9.1 mm ±0.10 mm
TA04632 B Page 2 of 2© 2011 Thomas & Betts. All Rights Reserved.
Loading...