Instruction Sheet PRO-CRIMPER*IIIHandCrimping ToolAssembly90575-1with 408--9887 DieAssembly90575-2 27 OCT 09 RevC PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awide selection ofpowered application equipmentforextended--use,production operationsisavailable. Locator Assembly Stationary Jaw (Supplied with Die Assembly) Back of Tool (Wire Side) Front of Tool (Locator Side) Pivot Pin Die Assembly PRO--CRIMPER III Hand Crimping Tool Frame Moving Jaw 354940--1 (408--9930) Ratchet Adjustment Wheel The PRO--CRIMPER IIIHand Crimping Tool isa “Commercial”grade tool and isdesigned primarilyforfield installation,repair,maintenance work,or Stationary prototyping in industrial,commercial,orinstitutional applications.Product Handle crimped with thistool will meetthe crimp heightrequirementforhand toolsin the appropriate 114 seriesspecification,butmaynotcomplywith otherfeature parametersofthe specification.Tyco Electronicsoffersa varietyoftoolsto satisfyyourperformance requirements.Foradditional information,contactthe Moving Handle Tooling Assistance Centerat1--800--722--1111. Wire TE TEL Loc ocaattor or C Co onta ntacctt T TE ED DiieeA Asssem semb bllyy Assembly{ Family} Size(AWG) InsulDia StripLength 2.54 to 3.30 20--14 Commercial [.100 to .130] 4.37 4.37 tto o5.13 5.13 9 90575 0575--2 2 5 58515 8515--1 1 M MA AT TE E--N N--L LO OK K** [.172 to .202] (1) 18 and (1) 16 Contacts 2.92 [.115] Max or (2) 18 { Suppliedwithdieassembly.Alsoavailableseparately. } ContacttheTOOLING ASSISTANCE CENTER or PRODUCTINFORMATION (seebelow) for specific contactpartnumbers. Figure 1 Reasons for reissue are provided in Section 11, 1. INTRODUCTION REVISION SUMMARY. PRO--CRIMPER III Hand Crimping Tool Assembly 90575--1 consists of Die Assembly 90575--2 and PRO--CRIMPER III Hand Crimping Tool 2. DESCRIPTION (Figures1 and 2) Frame 354940--1. The die assembly consists of crimping dies and a locator assembly. The tool features a tool frame with a stationary jaw and handle, a moving jaw, a moving handle, and an Read these instructions thoroughly before crimping adjustable ratchet that ensures full contact crimping. any contacts. The tool frame holds a die assembly with two Dimensions on this sheet are in millimeters [with crimping sections. NOTE inch equivalents provided in brackets]. Figures and illustrations are for identification only and are The die assembly features a wire anvil, an insulation i not drawn to scale. anvil, a wire crimper, and an insulation crimper. E2009 Tyco Electronics Corporation, Harrisburg, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlled document is subject to change. 1 of 6 PRODUCT INFORMATION1--800--522--6752 Forlatest revision and Regional CustomerService, All International Rights Reserved visit ourwebsite atwww.tycoelectronics.com TE logo and Tyco Electronics are trademarks. LOCB *Trademark. Otherproducts, logos, and company names used are the property of theirrespective owners. 408-9887 PRO-CRIMPERIIIHandCrimpingToolAssembly90575-1 Locator Nut Assembly Tool Frame Locator Insulation Die Retaining Crimper Chamfer Pins Wire Crimper Offset Wire Anvil Chamfer Insulation Die Retaining Anvil Screws Figure 2 Attached to the outside of the frame is a locator screw just enough to hold the dies in place. Do not assembly, which contains a locator, a spring retainer, tighten the screw completely at this time. and a contact support. 8. Carefully close the tool handles, making sure Die retaining pins and die retaining screws are used that the anvils and crimpers align properly. to position and secure the dies in the tool frame. A Continue closing the tool handles until the ratchet nut is used on the upper die retaining screw to hold in the tool frame has engaged sufficiently to hold the locator assembly in place. the anvils and crimpers in place, then tighten both die retaining screws. 9. Place the locator assembly over the end of the 3. INSTALLATIONANDREMOVALOFDIESET long screw, and position the locator assembly ANDLOCATORASSEMBLY (Figure 2) against the side of the tool jaw. 1. Open the tool handles and remove the two die retaining screws from the tool jaws. 10. Place the nut onto the end of the long screw and tighten the nut enough to hold the locator 2. Place the wire anvil and insulation anvil so that assembly in place, while still allowing the locator to their chamfered sides and their marked surfaces slide up and down. face outward, when mounted in the moving jaw of the tool frame. 11. To disassemble, close the tool handles until the 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 4. Insert the short die retaining screw through the crimpers 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 tighten the screw completely at this time. 4. CONTACTSUPPORTADJUSTMENT (Figure 3) 5. Place the wire crimper and insulation crimper so The contact support is preset prior to shipment, NOTE that their chamfered sides and their marked but minor adjustment may be necessary. surfaces face outward, when mounted in the 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. 2 of 6 Tyco ElectronicsCorporation RevC 408-9887 PRO-CRIMPERIIIHandCrimpingToolAssembly90575-1 2. If adjustment is required, loosen the screw that Refer to the table in Figure 1 and select wire of the holds the contact support onto the locator specified size and insulation diameter. Strip the wire assembly. to the length indicated in Figure 1, taking care not to nick or cut wire strands. Select an applicable contact The ratchet has detents that create audible clicks NOTE and identify the appropriate crimp section according as the tool handles are closed. to the wire size markings on the tool. Refer to Figure 3 and proceed as follows: i 3. Place a contact with wire into the proper nest 1. Hold the tool so that the back (wire side) is and close the tool handles until the ratchet reaches facing you. Squeeze tool handles together and the sixth click, or until the contact support touches allow them to open fully. the contact. 4. Slightly loosen the nut that holds the locator 2. Holding the contact by the mating end, insert the assembly onto the tool frame. contact — insulation barrel first — through the front of the tool and into the appropriate crimp section. 5. Move the contact support as required to eliminate the bending of the contact. 3. Position the contact so that the mating end of 6. Tighten the nut and close the handles until the the contact is on the locator side of the tool, and so ratchet releases. that the open “U” of the wire and insulation barrels face the top of the tool. Place the contact up into 7. Remove and inspect the contact. the nest so that the movable locator drops into the 8. Make another sample crimp. If the contact is slot in the contact. Refer to Figure 3. Butt the front straight, tighten the contact support screw. If the end of the wire barrel against the movable locator. contact is still being bent during crimping, repeat the adjustment procedure. Make sure that both sides of the insulation barrel CAUTION are started evenly into the crimping section. Do 5. CRIMPINGPROCEDURE NOT attempt to crimp an improperly positioned ! contact. This tool is provided with a crimp adjustment NOTE feature. Initially, the crimp height should be verified as specified in Figure 4. Refer to i Section 6, CRIMP HEIGHT INSPECTION, and 4. Hold the contact in position and squeeze the Section 7, RATCHET ADJUSTMENT, to verify tool handles together until ratchet engages crimp height before using the tool to crimp sufficiently to hold the contact in position. Do NOT desired contacts and wire sizes. deform insulation barrel or wire barrel. Contact Locator Support 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 RevC Tyco ElectronicsCorporation 3 of 6 408-9887 PRO-CRIMPERIIIHandCrimpingToolAssembly90575-1 5. Insert stripped wire into contact insulation and crimp height conforms to that shown in the table, wire barrels until it is butted against the wire stop, the tool is considered dimensionally correct. If not, as shown in Figure 3. the tool must be adjusted. Refer to Section 7, RATCHET (Crimp Height) ADJUSTMENT. 6. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact. 7. RATCHET(CrimpHeight)ADJUSTMENT (Figure 5) 1. Remove the lockscrew from the ratchet The crimped contact may stick in the crimping NOTE adjustment wheel. area, but the contact can be easily removed by pushing downward on the top of the locator (see i Screwdriver Figure 3). 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. 6. CRIMPHEIGHTINSPECTION Ratchet Adjustment Crimp height inspection is performed through the use Wheel of a micrometer with a modified anvil, commonly referred to as a crimp--height comparator. Tyco Electronics does not manufacture or market crimp--height comparators. Detailed information on obtaining and using crimp--height comparators can be Lockscrew found in instruction sheet 408--7424. (Typ) Proceed as follows: Figure 5 1. Refer to Figure 4 and select a wire (maximum size) for each crimp section listed. 2. With a screwdriver, adjust the ratchet wheel from the locator side of the tool. 2. Refer to Section 5, CRIMPING PROCEDURE, and crimp the contact(s) accordingly. 3. Observe the ratchet adjustment wheel. If a tighter crimp is required, rotate the adjustment Position Point wheel COUNTERCLOCKWISE to a on Center of higher--numbered setting. If a looser crimp is Wire Barrel required, rotate the adjustment wheel Opposite CLOCKWISE to a lower--numbered setting. Seam 4. Replace the lockscrew. 5. Make a sample crimp and measure the crimp Modified Anvil “A” height. If the dimension is acceptable, replace and secure the lockscrew. If the dimension is CrimpHeight unacceptable, continue to adjust the ratchet, and Wir WireeS Siz izee Cri Crim mp pS Seect ctiio on n D Diim meen nssiio on nA A again measure a sample crimp. AWG (Max) (WireSizeMarking) (+0.05[+.002]) 1.35 + .05 14 20--14 8. MAINTENANCE [.053 + .002] Ensure that the tool and dies are clean by wiping (1) 18 1.63 + .05 15--14 them with a clean, soft cloth. Remove any debris with and (1) 16 [.064 + .002] a clean, soft brush. Do not use objects that could Figure 4 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. 3. Using a crimp--height comparator, measure the wire barrel crimp height as shown in Figure 4. If the 4 of 6 Tyco ElectronicsCorporation RevC 408-9887 PRO-CRIMPERIIIHandCrimpingToolAssembly90575-1 9. VISUALINSPECTION Order the repair kit and replaceable parts through your Tyco Electronics representative, or call The crimping dies should be inspected on a regular 1--800--526--5142, or send a facsimile of your basis to ensure that they have not become worn or purchase order to 1--717--986--7605, or write to: damaged. Inspect the crimp sections for flattened, CUSTOMER SERVICE (38--35) chipped, worn, or broken areas. If damage or TYCO ELECTRONICS abnormal wear is evident, the tool must be replaced. PO BOX 3608 See Section 10, REPLACEMENT. HARRISBURG PA 17105--3608 10. REPLACEMENT 11.REVISIONSUMMARY Customer--replaceable parts are shown in Figure 1. Revisions to this instruction sheet include: Available separately, PRO--CRIMPER III Hand S Changed PRO--CRIMPER II Hand Tool to Crimping Tool Repair Kit 679221--1 includes a PRO--CRIMPER III Hand Tool; replacement nut and a variety of pins, rings, screws, S Revised crimp--height comparator information; and springs. S Applied TE logo; If the dies are damaged or worn excessively, they S Updated format to current corporate must be replaced. requirements; and S Added back page indicating tooling compatible with dies 90575--2. RevC Tyco ElectronicsCorporation 5 of 6 408-9887 PRO-CRIMPERIIIHandCrimpingToolAssembly90575-1 ToolingUsedWithDies90575-2 PRO-CRIMPER III Hand Tool 354940-1 SDE PEW-12Hand Tool 9-1478240-0 (Instruction Sheet408-9930) (Instruction Sheet408-8851) SDE Bench Terminator1490076-2 626Adapter679304-1 (CustomerManual 409-10052) (Instruction Sheet408-4070) BatteryTool (Pin Die)1213890-1, -2 BatteryTool (Shouldered Die)1725837-1, -2 (CustomerManual 409-10065) (CustomerManual 409-10053) 6 of 6 Tyco ElectronicsCorporation RevC