PRO- CRIMPER* III Hand Instructon Sheet Crmpng Tool Assembly 90684-1 408-9934 wth De Assembly 90684-2 09 OCT 09 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended -use, producton operatons s avalable. Locator Assembly (Suppled wth De Assembly) Front of Tool (Locator Sde) Statonary Jaw Pvot Pn Back of Tool (Wre Sde) De Assembly Movng Jaw Ratchet Adjustment Wheel The PRO -CRIMPER III Hand Crmpng Tool s a Commercal grade tool and s desgned prmarly for feld nstallaton, repar, mantenance work, or prototypng n ndustral, commercal, or nsttutonal applcatons. Product crmped wth ths tool wll meet the crmp heght requrement for hand tools n the approprate 114 seres specfcaton, but may not comply wth other feature parameters of the specfcaton. Tyco Electroncs offers a varety of tools to satsfy your performance requrements. For addtonal nformaton, contact the Toolng Assstance Center at 1-800 -722-1111. Movng Handle PRO -CRIMPER III Hand Crmpng Tool Frame 354940-1 (408-9930) Statonary Handle TE De Assembly TE Locator Assembly{ Contact Wre Famly} Sze (AWG) Insul Da Strp Length 90684-2 58515-1 Dynamc D -3000 Seres Connectors 20-18 16 1.80 to 2.79 [.071 to.110] 2.18 to 2.79 [.086 to.110] 3.30 to 4.32 [.130 to.170] { Suppled wth de assembly. Also avalable separately. } Contact the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION (see below) for specfc contact part numbers. Fgure 1 1. INTRODUCTION PRO--CRIMPER III Hand Crmpng Tool Assembly 90684--1 conssts of De Assembly 90684--2 and PRO--CRIMPER III Hand Crmpng Tool Frame 354940--1. The de assembly conssts of crmpng des and a locator assembly. Read these nstructons thoroughly before crmpng any contacts. Dmensons on ths sheet are n mllmeters [wth nch equvalents provded n brackets]. Fgures and llustratons are fordentfcaton only and are not drawn to scale. Reasons for ressue are provded n Secton 11, REVISION SUMMARY. 2. DESCRIPTION (Fgures 1 and 2) The tool features a tool frame wth a statonary jaw and handle, a movng jaw, a movng handle, and an adjustable ratchet that ensures full contact crmpng. The tool frame holds a de assembly wth two crmpng sectons. The de assembly features a wre anvl, an nsulaton anvl, a wre crmper, and an nsulaton crmper. E2009 Tyco Electroncs Corporaton, Harrsburg, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Internatonal Rghts Reserved PRODUCT INFORMATION 1-800 -522-6752 TE logo and Tyco Electroncs are trademarks. *Trademark. Other products, logos, and company names used are the property of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.tycoelectroncs.com 1 of 6 LOC B
Nut Locator Assembly Tool Frame Locator Chamfer Insulaton Crmper De Retanng Pns Wre Crmper Offset Wre Anvl Insulaton Anvl Chamfer De Retanng Screws Attached to the outsde of the frame s a locator assembly, whch contans a locator, a sprng retaner, and a contact support. De retanng pns and de retanng screws are used to poston and secure the des n the tool frame. A nut s used on the upper de retanng screw to hold the locator assembly n place. 3. INSTALLATION AND REMOVAL OF DIE SET AND LOCATOR ASSEMBLY (Fgure 2) 1. Open the tool handles and remove the two de retanng screws from the tool jaws. 2. Place the wre anvl and nsulaton anvl so that ther chamfered sdes and ther marked surfaces face outward, when mounted n the movng jaw of the tool frame. 3. Insert the two de retanng pns. 4. Insert the short de retanng screw through the jaw and through both anvl des, and tghten the screw just enough to hold the des n place. Do not tghten the screw completely at ths tme. 5. Place the wre crmper and nsulaton crmper so that ther chamfered sdes and ther marked Fgure 2 surfaces face outward, when mounted n the statonary jaw of the tool frame. 6. Insert the two de retanng pns. 7. Insert the long de retanng screw through the jaw and through both crmper des, and tghten the screw just enough to hold the des n place. Do not tghten the screw completely at ths tme. 8. Carefully close the tool handles, makng sure that the anvls and crmpers algn properly. Contnue closng the tool handles untl the ratchet n the tool frame has engaged suffcently to hold the anvls and crmpers n place, then tghten both de retanng screws. 9. Place the locator assembly over the end of the long screw, and poston the locator assembly aganst the sde of the tool jaw. 10. Place the nut onto the end of the long screw and tghten the nut enough to hold the locator assembly n place, whle stll allowng the locator to slde up and down. 11. To dsassemble, close the tool handles untl the ratchet releases, remove the nut, the locator assembly, the two de retanng screws, and the four de retanng pns, and slde the anvls and crmpers out of the tool jaws. 2 of 6 Tyco Electroncs Corporaton
4. CONTACT SUPPORT ADJUSTMENT (Fgure 3) The contact support s preset pror to shpment, but mnor adjustment may be necessary. 1. Make a sample crmp and determne f the contact s straght, bendng upward, or bendng downward. 2. If adjustment s requred, loosen the screw that holds the contact support onto the locator assembly. The ratchet has detents that create audble clcks as the tool handles are closed. 3. Place a contact wth wre nto the proper nest and close the tool handles untl the ratchet reaches the sxth clck, or untl the contact support touches the contact. 4. Slghtly loosen the nut that holds the locator assembly onto the tool frame. 5. Move the contact support as requred to elmnate the bendng of the contact. 6. Tghten the nut and close the handles untl the ratchet releases. 7. Remove and nspect the contact. 8. Make another sample crmp. If the contact s straght, tghten the contact support screw. If the contact s stll beng bent durng crmpng, repeat the adjustment procedure. 5. CRIMPING PROCEDURE Ths tool s provded wth a crmp adjustment feature. Intally, the crmp heght should be verfed as specfed n Fgure 4. Refer to Secton 6, CRIMP HEIGHT INSPECTION, and Secton 7, RATCHET ADJUSTMENT, to verfy crmp heght before usng the tool to crmp desred contacts and wre szes. Refer to the table n Fgure 1 and select wre of the specfed sze and nsulaton dameter. Strp the wre to the length ndcated n Fgure 1, takng care not to nck or cut wre strands. Select an applcable contact and dentfy the approprate crmp secton accordng to the wre sze markngs on the tool. Refer to Fgure 3 and proceed as follows: 1. Hold the tool so that the back (wre sde) s facng you. Squeeze tool handles together and allow them to open fully. 2. Holdng the contact by the matng end, nsert the contact nsulaton barrel frst through the front of the tool and nto the approprate crmp secton. 3. Poston the contact so that the matng end of the contact s on the locator sde of the tool, and so that the open U of the wre and nsulaton barrels face the top of the tool. Place the contact up nto the nest so that the movable locator drops nto the slot n the contact. Refer to Fgure 3. Butt the front end of the wre barrel aganst the movable locator. CAUTION! Make sure that both sdes of the nsulaton barrel are started evenly nto the crmpng secton. Do NOT attempt to crmp an mproperly postoned contact. Contact Support Locator Adjustment Screw for Contact Support Back of Tool (Wre Sde) Contact (Typ) Strp Length Wre Locator n Wre Stop Slot Wre Inserted to Stop Fgure 3 Tyco Electroncs Corporaton 3 of 6
4. Hold the contact n poston and squeeze the tool handles together untl ratchet engages suffcently to hold the contact n poston. Do NOT deform nsulaton barrel or wre barrel. 5. Insert strpped wre nto contact nsulaton and wre barrels untl t s butted aganst the wre stop, as shown n Fgure 3. 6. Holdng the wre n place, squeeze tool handles together untl ratchet releases. Allow tool handles to open and remove crmped contact. The crmped contact may stck n the crmpng area, but the contact can be easly removed by pushng downward on the top of the locator (see Fgure 3). 2. Refer to Secton 5, CRIMPING PROCEDURE, and crmp the contact(s) accordngly. 3. Usng a crmp heght comparator, measure the wre barrel crmp heght as shown n Fgure 4. If the crmp heght conforms to that shown n the table, the tool s consdered dmensonally correct. If not, the tool must be adjusted. Refer to Secton 7, RATCHET (Crmp Heght) ADJUSTMENT. 7. RATCHET (Crmp Heght) ADJUSTMENT (Fgure 5) 1. Remove the lockscrew from the ratchet adjustment wheel. Screwdrver 7. Check the contact s crmp heght as descrbed n Secton 6, CRIMP HEIGHT INSPECTION. If necessary, adjust the crmp heght as descrbed n Secton 7, RATCHET (Crmp Heght) ADJUSTMENT. 6. CRIMP HEIGHT INSPECTION Crmp heght nspecton s performed through the use of a mcrometer wth a modfed anvl, commonly referred to as a crmp--heght comparator. Tyco Electroncs does not manufacture or market crmp--heght comparators. Detaled nformaton on obtanng and usng crmp--heght comparators can be found n nstructon sheet 408--7424. Proceed as follows: 1. Refer to Fgure 4 and select a wre (maxmum sze) for each crmp secton lsted. Poston Pont on Center of Wre Barrel Opposte Seam Modfed Anvl A Ratchet Adjustment Wheel Lockscrew (Typ) Fgure 5 2. Wth a screwdrver, adjust the ratchet wheel from the locator sde of the tool. 3. Observe the ratchet adjustment wheel. If a tghter crmp s requred, rotate the adjustment wheel COUNTERCLOCKWISE to a hgher--numbered settng. If a looser crmp s requred, rotate the adjustment wheel CLOCKWISE to a lower--numbered settng. 4. Replace the lockscrew. Wre Sze Crmp Secton AWG (Max) (Wre Sze Markng) 18 20-18 16 16 Fgure 4 Crmp Heght Dmenson A (and Tolerance +) 1.130 +.088 [.0445 +.0035] 1.435 +.088 [.0565 +.0035] 5. Make a sample crmp and measure the crmp heght. If the dmenson s acceptable, replace and secure the lockscrew. If the dmenson s unacceptable, contnue to adjust the ratchet, and agan measure a sample crmp. 4 of 6 Tyco Electroncs Corporaton
8. MAINTENANCE Ensure that the tool and des are clean by wpng them wth a clean, soft cloth. Remove any debrs wth a clean, soft brush. Do not use objects that could damage the tool. When not n use, keep handles closed to prevent objects from becomng lodged n the crmpng des, and store n a clean, dry area. 9. VISUAL INSPECTION The crmpng des should be nspected on a regular bass to ensure that they have not become worn or damaged. Inspect the crmp sectons for flattened, chpped, worn, or broken areas. If damage or abnormal wear s evdent, the tool must be replaced. See Secton 10, REPLACEMENT. 10. REPLACEMENT Customer--replaceable parts are shown n Fgure 1. Avalable separately, PRO--CRIMPER III Hand Crmpng Tool Repar Kt 679221--1 ncludes a replacement nut and a varety of pns, rngs, screws, and sprngs. If the des are damaged or worn excessvely, they must be replaced. Order the repar kt and replaceable parts through your Tyco Electroncs representatve, or call 1--800--526--5142, or send a facsmle of your purchase order to 1--717--986--7605, or wrte to: CUSTOMER SERVICE (38--35) TYCO ELECTRONICS PO BOX 3608 HARRISBURG PA 17105--3608 11.REVISION SUMMARY Revsons to ths nstructon sheet nclude: S Changed PRO--CRIMPER II Hand Tool to PRO--CRIMPER III Hand Tool; S Revsed crmp--heght comparator nformaton; S Appled TE logo; S Updated format to current corporate requrements; and S Added back page ndcatng toolng compatble wth des 90684--2. Tyco Electroncs Corporaton 5 of 6
Toolng Used Wth Des 90684-2 PRO-CRIMPER III Hand Tool 354940-1 (Instructon Sheet 408-9930) SDE PEW- 12 Hand Tool 9-1478240- 0 (Instructon Sheet 408-8851) SDE Bench Termnator 1490076-2 (Customer Manual 409-10052) 626 Adapter 679304-1 (Instructon Sheet 408-4070) Battery Tool (Shouldered De) 1725837-1, - 2 (Customer Manual 409-10053) Battery Tool (Pn De) 1213890-1, - 2 (Customer Manual 409-10065) 6 of 6 Tyco Electroncs Corporaton
Mouser Electroncs Authorzed Dstrbutor Clck to Vew Prcng, Inventory, Delvery & Lfecycle Informaton: TE Connectvty: 90684-1