Instruction Sheet PRO-CRIMPER*IIIHand CrimpingToolAssembly90870-1 408--9965 withDieAssembly90870-2 30 SEP 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 30--28 ..0 062 62C Co ommer mmerccial ial 3.05 3.05 + + 0.38 0.38 9 90870 0870--2 2 5 58516 8516--1 1 1 1.52 52 [[.060 060]] M Ma axx Pin and Socket [.120 + .015] 26--24 {Supplied with die assembly.Also available separately. }Contactthe Tooling Assistance CenterorProducrInformation (see below)forspecific contactpartnumbers. Figure 1 Reasons for reissue are provided in Section 11, 1. INTRODUCTION REVISION SUMMARY. PRO--CRIMPER III Hand Crimping Tool Assembly 90870--1 consists of Die Assembly 90870--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. 408-9965 PRO-CRIMPERIIIHandCrimpingToolAssembly90870-1 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 surfaces face outward, when mounted in the assembly, which contains a locator, a spring retainer, stationary jaw of the tool frame. and a contact support. 6. Insert the two die retaining pins. Die retaining pins and die retaining screws are used 7. Insert the long die retaining screw through the to position and secure the dies in the tool frame. A jaw and through both crimper dies, and tighten the nut is used on the upper die retaining screw to hold screw just enough to hold the dies in place. Do not the locator assembly in place. tighten the screw completely at this time. 8. Carefully close the tool handles, making sure 3. INSTALLATIONANDREMOVALOFDIESET that the anvils and crimpers align properly. ANDLOCATORASSEMBLY (Figure 2) Continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold 1. Open the tool handles and remove the two die the anvils and crimpers in place, then tighten both retaining screws from the tool jaws. die retaining screws. 2. Place the wire anvil and insulation anvil so that 9. Place the locator assembly over the end of the their chamfered sides and their marked surfaces long screw, and position the locator assembly face outward, when mounted in the moving jaw of against the side of the tool jaw. the tool frame. 10. Place the nut onto the end of the long screw 3. Insert the two die retaining pins. and tighten the nut enough to hold the locator assembly in place, while still allowing the locator to 4. Insert the short die retaining screw through the slide up and down. jaw and through both anvil dies, and tighten the 11. To disassemble, close the tool handles until the screw just enough to hold the dies in place. Do not ratchet releases, remove the nut, the locator tighten the screw completely at this time. assembly, the two die retaining screws, and the 5. Place the wire crimper and insulation crimper so four die retaining pins, and slide the anvils and that their chamfered sides and their marked crimpers out of the tool jaws. 2 of 6 Tyco ElectronicsCorporation RevC 408-9965 PRO-CRIMPERIIIHandCrimpingToolAssembly90870-1 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 the contact is on the locator side of the tool, and so 5. Move the contact support as required to that the open “U” of the wire and insulation barrels eliminate the bending of the contact. 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 (Wire Side) Adjustment Screw for Contact Strip Support Contact Length (Typ) Locator Wire in Wire Wire Stop Slot Inserted to Stop Figure 3 RevC Tyco ElectronicsCorporation 3 of 6 408-9965 PRO-CRIMPERIIIHandCrimpingToolAssembly90870-1 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. 2. With a screwdriver, adjust the ratchet wheel from the locator side of the tool. 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 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 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 (Typ) found in instruction sheet 408--7424. Proceed as follows: Figure 5 1. Refer to Figure 4 and select a wire (maximum size) for each crimp section listed. 3. Observe the ratchet adjustment wheel. If a tighter crimp is required, rotate the adjustment 2. Refer to Section 5, CRIMPING PROCEDURE, wheel COUNTERCLOCKWISE to a and crimp the contact(s) accordingly. higher--numbered setting. If a looser crimp is required, rotate the adjustment wheel Position Point CLOCKWISE to a lower--numbered setting. on Center of 4. Replace the lockscrew. Wire Barrel Opposite 5. Make a sample crimp and measure the crimp Seam height. If the dimension is acceptable, replace and secure the lockscrew. If the dimension is unacceptable, continue to adjust the ratchet, and Modified Anvil “A” again measure a sample crimp. Wir WireeS Siz izee Cri Crim mp pS Seect ctiio on n Cri Crim mp pHe Heiig ght ht 8. MAINTENANCE AWG(Max) (WireSizeMarking) DimensionA Ensure that the tool and dies are clean by wiping 28 30--28 0.58 [.023] them with a clean, soft cloth. Remove any debris with a clean, soft brush. Do not use objects that could 24 26--24 0.64 [.025] damage the tool. When not in use, keep handles closed to prevent objects from becoming lodged in Figure 4 the crimping dies, and store in a clean, dry area. 4 of 6 Tyco ElectronicsCorporation RevC 408-9965 PRO-CRIMPERIIIHandCrimpingToolAssembly90870-1 9. VISUALINSPECTION 1--800--526--5142, or send a facsimile of your purchase order to 1--717--986--7605, or write to: The crimping dies should be inspected on a regular basis to ensure that they have not become worn or CUSTOMER SERVICE (38--35) damaged. Inspect the crimp sections for flattened, TYCO ELECTRONICS chipped, worn, or broken areas. If damage or PO BOX 3608 abnormal wear is evident, the tool must be replaced. HARRISBURG PA 17105--3608 See Section 10, REPLACEMENT. 11.REVISIONSUMMARY 10. REPLACEMENT Revisions to this instruction sheet include: Customer--replaceable parts are shown in Figure 1. S Changed PRO--CRIMPER II Hand Tool to Available separately, PRO--CRIMPER III Hand PRO--CRIMPER III Hand Tool; Crimping Tool Repair Kit 679221--1 includes a S Changed Crimp--Height Comparator replacement nut and a variety of pins, rings, screws, information; and springs. S Updated format to current corporate If the dies are damaged or worn excessively, they requirements; must be replaced. S Applied the TE logo; and Order the repair kit and replaceable parts through S Added back page to illustrate tooling varieties your Tyco Electronics representative, or call that accept Die Set Assembly 90870--2. RevC Tyco ElectronicsCorporation 5 of 6 408-9965 PRO-CRIMPERIIIHandCrimpingToolAssembly90870-1 ToolingUsedWithDies90870-2 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