Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 90548-1 with 408-9885 Die Assembly 90548-2 02 NOV 12 Rev G PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume applications. A wide selection of powered application equipment for extended-use, production operations is available. Locator Assembly Stationary Jaw (Supplied with Die Back of Tool Assembly) (Wire Side) Front of Tool Pivot Pin (Locator Side) Die Assembly PRO-CRIMPER III Hand Crimping Tool Frame Moving Jaw 354940-1 (408-9930) Ratchet Adjustment Wheel Stationary Handle The PRO-CRIMPER III Hand Crimping Tool is a “Commercial” grade tool and is designed primarily for field installation, repair, maintenance work, or prototyping in industrial, Moving Handle commercial, or institutional applications. Product crimped with this tool will meet the crimp height requirement for hand tools in the appropriate 114 series specification, but may not comply with other feature parameters of the specification. This company offers a variety of tools to satisfy your performance requirements. For additional information, contact the Tooling Assistance Center at 1-800-722-1111. WIRE DIE LOCATOR CONTACT ASSEMBLY ASSEMBLY † FAMILY ‡ SIZE (AWG) INSUL DIA STRIP LENGTH Universal 24-22 1.02 to 2.54 3.96 to 4.75 90548-2 58515-1 MATE-N-LOK* [.040 to .100] [.156 to .187] 20-18 Contacts † Supplied with die assembly. Also available separately ‡ Contact the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION (see below) for specific contact part numbers. Figure 1 1. INTRODUCTION Reasons for reissue are provided in Section 11, REVISION SUMMARY. PRO-CRIMPER III Hand Crimping Tool Assembly 90548-1 consists of Die Assembly 90548-2 and 2. DESCRIPTION (Figure 1 and Figure 2) PRO-CRIMPER III Hand Crimping Tool Frame 354940-1. The die assembly consists of crimping dies The tool features a tool frame with a stationary jaw and a locator assembly. and handle, a moving jaw, a moving handle, and an adjustable ratchet that ensures full contact crimping. Read these instructions thoroughly before crimping The tool frame holds a die assembly with two crimping any contacts. sections. Dimensions on this sheet are in millimeters [with NOTE The die assembly features a wire anvil, an insulation inch equivalents provided in brackets]. Figures and anvil, a wire crimper, and an insulation crimper. illustrations are for identification only and are not i drawn to scale. Attached to the outside of the frame is a locator assembly, which contains a locator, a spring retainer, and a contact support. ©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS 408-9885 Nut Locator Assembly Tool Frame Locator Insulation Die Retaining Crimper Chamfer Pins Wire Crimper Offset Wire Anvil Insulation Chamfer Die Retaining Anvil Screws Figure 2 Die retaining pins and die retaining screws are used to closing the tool handles until the ratchet in the tool position and secure the dies in the tool frame. A nut is frame has engaged sufficiently to hold the anvils used on the upper die retaining screw to hold the and crimpers in place, then tighten both die locator assembly in place. retaining screws. 9. Place the locator assembly over the end of the 3. INSTALLATION AND REMOVAL OF DIE SET AND long screw, and position the locator assembly LOCATOR ASSEMBLY (Figure 2) against the side of the tool jaw. 1. Open the tool handles and remove the two die 10. Place the nut onto the end of the long screw and retaining screws from the tool jaws. tighten the nut enough to hold the locator assembly 2. Place the wire anvil and insulation anvil so that in place, while still allowing the locator to slide up their chamfered sides and their marked surfaces and down. face outward, when mounted in the moving jaw of 11. To disassemble, close the tool handles until the the tool frame. ratchet releases, remove the nut, the locator 3. Insert the two die retaining pins. assembly, the two die retaining screws, and the four die retaining pins, and slide the anvils and crimpers 4. Insert the short die retaining screw through the out of the tool jaws. jaw and through both anvil dies, and tighten the screw just enough to hold the dies in place. Do not 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) tighten the screw completely at this time. 5. Place the wire crimper and insulation crimper so that their chamfered sides and their marked The contact support is preset prior to shipment, but NOTE surfaces face outward, when mounted in the minor adjustment may be necessary. stationary jaw of the tool frame. i 6. Insert the two die retaining pins. 1. Make a sample crimp and determine if the 7. Insert the long die retaining screw through the contact is straight, bending upward, or bending jaw and through both crimper dies, and tighten the downward. screw just enough to hold the dies in place. Do not 2. If adjustment is required, loosen the screw that tighten the screw completely at this time. holds the contact support onto the locator assembly. 8. Carefully close the tool handles, making sure that the anvils and crimpers align properly. Continue Rev G 2 of 6 408-9885 The ratchet has detents that create audible clicks Refer to the table in Figure 1 and select wire of the NOTE as the tool handles are closed. specified size and insulation diameter. Strip the wire to the length indicated in Figure 1, taking care not to nick i or cut wire strands. Select an applicable contact and identify the appropriate crimp section according to the 3. Place a contact with wire into the proper nest and wire size markings on the tool. Refer to Figure 3 and close the tool handles until the ratchet reaches the proceed as follows: sixth click, or until the contact support touches the contact. 1. Hold the tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them 4. Slightly loosen the nut that holds the locator to open fully. assembly onto the tool frame. 2. Holding the contact by the mating end, insert the 5. Move the contact support as required to eliminate contact - insulation barrel first - through the front of the bending of the contact. the tool and into the appropriate crimp section. 6. Tighten the nut and close the handles until the 3. Position the contact so that the mating end of the ratchet releases. contact is on the locator side of the tool, and so that 7. Remove and inspect the contact. the open “U” of the wire and insulation barrels face the top of the tool. Place the contact up into the nest 8. Make another sample crimp. If the contact is so that the movable locator drops into the slot in the straight, tighten the contact support screw. If the contact. Refer to Figure 3. Butt the front end of the contact is still being bent during crimping, repeat the wire barrel against the movable locator. adjustment procedure. Make sure that both sides of the insulation barrel CAUTION 5. CRIMPING PROCEDURE are started evenly into the crimping section. Do not This tool is provided with a crimp adjustment attempt to crimp an improperly positioned contact. NOTE ! feature. Initially, the crimp height should be verified as specified in Figure 4. Refer to Section 6, Crimp i 4. Hold the contact in position and squeeze the tool Height Inspection, and Section 7, RATCHET handles together until ratchet engages sufficiently to Adjustment, to verify crimp height before using the hold the contact in position. Do NOT deform tool to crimp desired contacts and wire sizes. insulation barrel or wire barrel. Contact Support Locator Back of Tool Adjustment (Wire Side) Screw for Contact Support Contact Strip (Typ) Length Wire Locator in Wire Stop Slot Wire Inserted to Stop Figure 3 Rev G 3 of 6 408-9885 5. Insert stripped wire into contact insulation and 7. RATCHET (Crimp Height) ADJUSTMENT (FIGURE 5) wire barrels until it is butted against the wire stop, as 1. Remove the lockscrew from the ratchet shown in Figure 3. adjustment wheel. 6. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact. Screwdriver The crimped contact may stick in the crimping area, NOTE but the contact can be easily removed by pushing downward on the top of the locator (see Figure 3). i 7. Check the contact's crimp height as described in Section 6, Crimp Height Inspection. If necessary, adjust the crimp height as described in Section 7, RATCHET (Crimp Height) ADJUSTMENT. Ratchet Adjustment 6. CRIMP HEIGHT INSPECTION Wheel Crimp height inspection is performed through the use of a micrometer with a modified anvil, commonly referred to as a crimp-height comparator. TE does not manufacture or market crimp-height comparators. Lockscrew Detailed information on obtaining and using crimp- (Typ) height comparators can be found in instruction sheet 408-7424. Figure 5 Proceed as follows: 2. With a screwdriver, adjust the ratchet wheel from 1. Refer to Figure 4 and select a wire (maximum the locator side of the tool. size) for each crimp section listed. 3. Observe the ratchet adjustment wheel. If a tighter 2. .Refer to Section 5, CRIMPING PROCEDURE, crimp is required, rotate the adjustment wheel and crimp the contact(s) accordingly. COUNTERCLOCKWISE to a higher-numbered 3. Using a crimp-height comparator, measure the setting. If a looser crimp is required, rotate the wire barrel crimp height as shown in Figure 4. If the adjustment wheel CLOCKWISE to a lower- crimp height conforms to that shown in the table, numbered setting. the tool is considered dimensionally correct. If not, 4. Replace the lockscrew. the tool must be adjusted. Refer to Section 7, RATCHET (Crimp Height) ADJUSTMENT. 5. Make a sample crimp and measure the crimp height. If the dimension is acceptable, replace and secure the lockscrew. If the dimension is Position Point unacceptable, continue to adjust the ratchet, and on Center of again measure a sample crimp. Wire Barrel Opposite 8. MAINTENANCE Seam Ensure that the tool and dies are clean by wiping them with a clean, soft cloth. Remove any debris with a Modified clean, soft brush. Do not use objects that could Anvil damage the tool. When not in use, keep handles closed to prevent objects from becoming lodged in the crimping dies, and store in a clean, dry area. CRIMP SECTION CRIMP HEIGHT WIRE SIZE (Wire Size DIM “A” AND 9. VISUAL INSPECTION AWG (Max) Marking) TOLERANCE (±) The crimping dies should be inspected on a regular basis to ensure that they have not become worn or 1.02 ±0.05 22 24-22 [.040 ±.002] damaged. Inspect the crimp sections for flattened, chipped, worn, or broken areas. If damage or 1.17 ±0.05 18 20-18 abnormal wear is evident, the tool must be replaced. [.046 ±.002] See Section 10, REPLACEMENT. Figure 4 Rev G 4 of 6 408-9885 10. REPLACEMENT Order the repair kit and replaceable parts through your company representative, or call 1-800-526-5142, or Customer-replaceable parts are shown in Figure 1. send a facsimile of your purchase order to 1-717-986-7605, or write to: Available separately, PRO-CRIMPER III Hand Crimping Tool Repair Kit 679221-1 includes a CUSTOMER SERVICE (038-035) replacement nut and a variety of pins, rings, screws, TYCO ELECTRONICS CORPORATION and springs. PO BOX 3608 If the dies are damaged or worn excessively, they HARRISBURG PA 17105-3608 must be replaced. 11. REVISION SUMMARY • Corrected dimension in table in Figure 4 Rev G 5 of 6 408-9885 Tooling Compatible with Die Assembly 90548-2 PRO-CRIMPER III Hand Tool Frame 354940-1 SDE-SA Hand Tool 9-1478240-0 (Instruction Sheet 408-9930) (Instruction Sheet 408-8851) SDE Bench Terminator 1490076-2 626 Adapter 679304-1 (Customer Manual 409-10052) (Instruction Sheet 408-4070) Electro-Hydraulic (BT 3500 Battery-Hydraulic) Closed Head Assembly 2031460-1 “C”-Head Assembly 2031450-1 Hand Tool Kits 2031400-[ ] (Instruction Sheet 408-10312) (Instruction Sheet 408-10311) (Customer Manual 409-10095) Rev G 6 of 6