Daniels Manufacturing Corporation Tooling for Harness Assembly

Team members required: One

Description:

This event will test each participant’s skill in repairing and securing a wire harness. Contestants will remove one wire and properly terminate contacts on a new pre-stripped wire. They will be responsible for assembling the turret head onto the crimp tool and adjusting the tool and accessory to the correct setting. Next, they will insert the new wire into both connectors and test if they are properly inserted. Contestants will then secure the wire bundle using the LaceLok. tool. Finally, contestants will verify the calibration of the Safe-T-Cable tool using the verification block and torque wrench. They will then identify the appropriate ferrule and apply Safe-T-Cable to secure the jam nut on one connector. Before completing the competition, contestants should return the torque wrench to zero, remove the cable applied to the verification block, and return all tools to their original location.

References:

https://dmctools.com/amc

Tools and equipment list:

• AF8 Crimp Tool
• TH1A Turret Head
• DAK16B Insertion Tool
• DRK16B Removal Tool
• HT210-16 Contact Retention Tester
• DLT-1100 LaceLok Application Tool

• LF2-10NA1 LaceLok
• MG-1300 LaceLok Cutters
• SCTR327 Safe-T-Cable® Tool
• A10-218 Cable (.032 x 18” safety cables)
• F10-04PKG Elongated Ferrules
• F10-2PKG Standard Ferrules
• SCT-TB1 Verification Block

• SCTD0001 Torque Wrench
• SCTD013 Push Force Tester
• 45-6N Safe-T-Cable Cutters
• M22759/34-16-9 28” Pre-stripped Wire
• M39029/32-247 Contacts
• MS3124F20-16S Connectors

Instructions:

A) Use the removal tool to remove a wire and contact from each connector.

B) Terminate a contact onto each end of a new piece of wire. Ensure the crimp tool and turret are set to the appropriate settings.

C) Use the insertion tool to insert the newly terminated wire into the connectors.

D) Use the contact retention tester to check that both contacts are properly seated in the connectors.

E) Starting 2 inches away from the connectors, apply (5) LaceLok at even intervals.

F) Check the calibration of the Safe-T-Cable tool with the provided verification equipment (verification block, torque wrench, and push force tester). Return the torque wrench to zero and remove the cable from the verification block.

G) Use the Safe-T-Cable tool and elongated ferrules to secure the jam nut on one connector. Teams will receive a bonus for a second correctly installed piece of Safe-T-Cable.

H) Dispose of FOD in the white tray and finish the competition by returning all tools to their original position.

Scoring:

Scores will be calculated according to the standard score sheet. Additional penalties may be assessed for incorrect Safe-T-Cable/LaceLok applications, improperly seated contacts, and missed portions of the competition. Bonus points will be given for an additional installation of Safe-T-Cable.