Daniels Manufacturing Corporation Tooling for Harness Assembly

Competitors Required:

1

Description:

This event will test each participant’s ability to repair and secure a wire harness using approved wiring practices and techniques.

References:

https://dmctools.com/amc

Tools, Equipment, and Materials Provided:

• M22759/34-16-9 28” Pre-stripped Wire
• M39029/32-247 Contacts
• MS3124F20-16S Connectors
• Crimp Tool (AF8)
• Turret Head (TH1A)
• Insertion Tool (DAK16B)
• Removal Tool (DRK16B)
• Contact Retention Tester (HT210-16)
• LaceLok Application Tool (DLT-1100)
• LaceLok (LF2-10NA1)
• LaceLok Cutters (MG-1300)
• Safe-T-Cable® Tool (SCTR327)
• Cable (.032 x 18” safety cables) (A10-218)
• Elongated Ferrules (F10-04PKG)
• Standard Ferrules (F10-2PKG)
• Verification Block (SCT-TB1)
• Torque Wrench (SCTD0001)
• Push Force Tester (SCTD013)
• Safe-T-Cable Cutters (45-6N)

Snap-on provided tooling (qty one in each of two pallets unless otherwise indicated): None

Procedures:

1. 1. Use the removal tool to remove a wire and contact from each connector.
   2. Terminate a contact onto each end of a new piece of wire. Ensure the crimp tool and turret are set to the appropriate settings.
   3. Use the insertion tool to insert the newly terminated wire into the connectors.
   4. Use the contact retention tester to check that both contacts are properly seated in the connectors.
   5. Starting 2 inches away from the connectors, apply (5) LaceLok at even intervals.
   6. Check the calibration of the Safe-T-Cable tool with the provided verification equipment (verification block, torque wrench, and push force tester) and standard ferrules.
   7. Return the torque wrench to zero and remove the cable from the verification block.
   8. Contestants will then identify the appropriate ferrule and apply Safe-T-Cable to secure the jam nut on one connector. Teams will receive a bonus for a second correctly installed piece of Safe-T-Cable.
   9. Dispose of FOD in the white tray and finish the competition by returning all tools to their original position (return the torque wrench to zero, remove the cable applied to the verification block, and return all tools to their original location).

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 correct installation of Safe-T-Cable.