TE CONNECTIVITY 90759-2

Instruction Sheet PRO-CRIMPER*IIIHand CrimpingToolAssembly90759-1 408--9962 withDieAssembly90759-2 03 MAY 11 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.TEConnectivityoffersa 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 3.20 to 3.71 1.50 to 2.39 22--20 MiniUniversal [.059 to .094] [.126 to .146] 9 90759 0759--2 2 5 58516 8516--1 1 M MA AT TE E--N N--L LO OK K** O OR R (2) 3.38 max Connectors (2) 3.50to3.99 18, (2) 22 [(2) .133 max] [(2) .138 to .157] { Suppliedwithdieassembly.Alsoavailableseparately. } ContacttheTOOLING ASSISTANCECENTER or PRODUCTINFORMATION (seebelow) for specific contactpartnumbers. Figure 1 1. INTRODUCTION any contacts. PRO--CRIMPER III Hand Crimping Tool Dimensions on this sheet are in millimeters [with NOTE Assembly 90759--1 consists of Die Assembly inch equivalents provided in brackets]. Figures 90759--2 and PRO--CRIMPER III Hand Crimping Tool and illustrations are for identification only and are i Frame 354940--1. The die assembly consists of not drawn to scale. crimping dies and a locator assembly. Reasons for reissue are provided in Section 11, Read these instructions thoroughly before crimping REVISION SUMMARY. E2011 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 LOCB TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-9962 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 2. DESCRIPTION (Figures1 and 2) screw just enough to hold the dies in place. Do not tighten the screw completely at this time. The tool features a tool frame with a stationary jaw 5. Place the wire crimper and insulation crimper so and handle, a moving jaw, a moving handle, and an that their chamfered sides and their marked adjustable ratchet that ensures full contact crimping. The tool frame holds a die assembly with two surfaces face outward, when mounted in the crimping sections. stationary jaw of the tool frame. 6. Insert the two die retaining pins. The die assembly features a wire anvil, an insulation anvil, a wire crimper, and an insulation crimper. 7. Insert the long die retaining screw through the jaw and through both crimper dies, and tighten the 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. 3. INSTALLATIONANDREMOVALOFDIESET 9. Place the locator assembly over the end of the ANDLOCATORASSEMBLY (Figure 2) long screw, and position the locator assembly 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 4. Insert the short die retaining screw through the four die retaining pins, and slide the anvils and jaw and through both anvil dies, and tighten the crimpers out of the tool jaws. 2 of 6 RevC 408-9962 4. CONTACTSUPPORTADJUSTMENT (Figure 3) 5. CRIMPINGPROCEDURE The contact support is preset prior to shipment, NOTE This tool is provided with a crimp adjustment NOTE but minor adjustment may be necessary. feature. Initially, the crimp height should be verified as specified in Figure 4. Refer to i i Section 6, CRIMP HEIGHT INSPECTION, and Section 7, RATCHET ADJUSTMENT, to verify 1. Make a sample crimp and determine if the crimp height before using the tool to crimp contact is straight, bending upward, or bending desired contacts and wire sizes. downward. Refer to the table in Figure 1 and select wire of the 2. If adjustment is required, loosen the screw that specified size and insulation diameter. Strip the wire holds the contact support onto the locator to the length indicated in Figure 1, taking care not to assembly. nick or cut wire strands. Select an applicable contact and identify the appropriate crimp section according The ratchet has detents that create audible clicks NOTE to the wire size markings on the tool. Refer to as the tool handles are closed. Figure 3 and proceed as follows: i 1. Hold the tool so that the back (wire side) is facing you. Squeeze tool handles together and 3. Place a contact with wire into the proper nest allow them to open fully. and close the tool handles until the ratchet reaches the sixth click, or until the contact support touches 2. Holding the contact by the mating end, insert the the contact. contact — insulation barrel first — through the front of the tool and into the appropriate crimp section. 4. Slightly loosen the nut that holds the locator assembly onto the tool frame. 3. Position the contact so that the mating end of 5. Move the contact support as required to the contact is on the locator side of the tool, and so eliminate the bending of the contact. that the open “U” of the wire and insulation barrels face the top of the tool. Place the contact up into 6. Tighten the nut and close the handles until the the nest so that the movable locator drops into the ratchet releases. slot in the contact. Refer to Figure 3. Butt the front end of the wire barrel against the movable locator. 7. Remove and inspect the contact. 8. Make another sample crimp. If the contact is Make sure that both sides of the insulation barrel CAUTION straight, tighten the contact support screw. If the are started evenly into the crimping section. Do contact is still being bent during crimping, repeat NOT attempt to crimp an improperly positioned ! the adjustment procedure. contact. Contact Locator Support Back of Tool Adjustment (Wire Side) Screw for Contact Support Contact Strip (Typ) Length Locator in Wire Wire Stop Slot Wire Inserted to Stop Figure 3 RevC 3 of 6 408-9962 4. Hold the contact in position and squeeze the 3. Using a crimp height comparator, measure the tool handles together until ratchet engages wire barrel crimp height as shown in Figure 4. If the sufficiently to hold the contact in position. Do NOT crimp height conforms to that shown in the table, deform insulation barrel or wire barrel. the tool is considered dimensionally correct. If not, the tool must be adjusted. Refer to Section 7, 5. Insert stripped wire into contact insulation and RATCHET (Crimp Height) ADJUSTMENT. wire barrels until it is butted against the wire stop, as shown in Figure 3. 7. RATCHET(CrimpHeight)ADJUSTMENT (Figure 5) 6. Holding the wire in place, squeeze tool handles 1. Remove the lockscrew from the ratchet together until ratchet releases. Allow tool handles adjustment wheel. to open and remove crimped contact. Screwdriver The crimped contact may stick in the crimping NOTE area, but the contact can be easily removed by pushing downward on the top of the locator (see i 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. Ratchet Adjustment Wheel 6. CRIMPHEIGHTINSPECTION 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 Lockscrew not manufacture or market crimp--height comparators. (Typ) Detailed information on obtaining and using crimp--height comparators can be found in instruction Figure 5 sheet 408--7424. 2. With a screwdriver, adjust the ratchet wheel Proceed as follows: from the locator side of the tool. 1. Refer to Figure 4 and select a wire (maximum 3. Observe the ratchet adjustment wheel. If a size) for each crimp section listed. tighter crimp is required, rotate the adjustment wheel COUNTERCLOCKWISE to a 2. Refer to Section 5, CRIMPING PROCEDURE, higher--numbered setting. If a looser crimp is and crimp the contact(s) accordingly. required, rotate the adjustment wheel CLOCKWISE to a lower--numbered setting. Position Point on Center of 4. Replace the lockscrew. Wire Barrel 5. Make a sample crimp and measure the crimp Opposite height. If the dimension is acceptable, replace and Seam secure the lockscrew. If the dimension is unacceptable, continue to adjust the ratchet, and again measure a sample crimp. Modified Anvil “A” 8. MAINTENANCE CrimpHeight Wir WireeS Siz izee Cri Crim mp pS Seect ctiio on n D Diim meen nssiio on nA A Ensure that the tool and dies are clean by wiping AWG (Max) (WireSizeMarking) (+0.05[+.002]) them with a clean, soft cloth. Remove any debris with a clean, soft brush. Do not use objects that could 20 22--20 .81 [.032] damage the tool. When not in use, keep handles 18 18, (2) 22 1.02 [.040] closed to prevent objects from becoming lodged in the crimping dies, and store in a clean, dry area. Figure 4 4 of 6 RevC 408-9962 Order the repair kit and replaceable parts through 9. VISUALINSPECTION your TE representative, or call 1--800--526--5142, or The crimping dies should be inspected on a regular send a facsimile of your purchase order to basis to ensure that they have not become worn or 1--717--986--7605, or write to: damaged. Inspect the crimp sections for flattened, chipped, worn, or broken areas. If damage or CUSTOMER SERVICE (38--35) abnormal wear is evident, the tool must be replaced. TYCO ELECTRONICS See Section 10, REPLACEMENT. PO BOX 3608 HARRISBURG PA 17105--3608 10. REPLACEMENT Customer--replaceable parts are shown in Figure 1. Available separately, PRO--CRIMPER III Hand 11.REVISIONSUMMARY Crimping Tool Repair Kit 679221--1 includes a replacement nut and a variety of pins, rings, screws, Revisions to this instruction sheet include: and springs. S Updated document to corporate requirements. If the dies are damaged or worn excessively, they must be replaced. RevC 5 of 6 408-9962 ToolingUsedWithDies90759-2 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 RevC