PRO-CRIMPER* III Hand Crmpng Tool Assembly 90758-1 wth De AssemblY 90758-2 Instructon Sheet 408-9938 01 NOV 11 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 De Assembly Front of Tool (Locator Sde) Movng Jaw Statonary Jaw Back of Tool Frame (Wre Sde) Pvot Pn PRO-CRIMPER III Hand Tool Frame 354940-1 (408-9930) ORIGINAL INSTRUCTIONS 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 Applcaton Specfcaton (114-seres), but may not comply wth other feature parameters of the specfcaton. TE Connectvty 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 Statonary Handle TE DIE ASSEMBLY TE LOCATOR ASSEMBLY 90758-2 58516-1 CONTACT FAMILY Mn Unversal MATE-N-LOK* Connectors WIRE SIZE (AWG) INSUL DIA STRIP LENGTH 26-22 1.19-1.75 [.047-.069] 3.20 to 3.71 [.126 to.146] 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 90758-1 conssts of De Assembly 90758-2 and PRO-CRIMPER III Hand Crmpng Tool Frame 354940-1 (see Instructon Sheet 408-9930). The de assembly conssts of crmpng des and a locator assembly. Read these nstructons thoroughly before crmpng any contacts. Dmensons n ths nstructon sheet are n mllmeters [wth nch equvalents provded n brackets]. Fgures and llustratons are for reference only and are not drawn to scale. Reasons for ressue of ths nstructon sheet are provded n Secton 11, REVISION SUMMARY. 2. DESCRIPTION (See Fgures 1 and 2) The tool consst of a statonary jaw and handle, a movng jaw and 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. Attached to the outsde of the frame s a locator assembly, whch contans a locator, 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. 2011 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 5 LOC B
Nut Locator Assembly Tool Frame Locator Chamfer Wre Crmper Insulaton Crmper De Retanng Pns Offset Wre Anvl Insulaton Anvl Chamfer De Retanng Screw De Retanng Screw Fgure 2 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 surfaces face outward, when mounted n the statonary jaw of the tool frame. 6. Insert the two 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. 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. 2 of 5
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 Secton7, 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. 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). 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. Contact Support Locator Adjustment Screw for Contact Support Back of Tool (Wre Sde) Contact (Typ) Strp Length Wre Locator n Wre Stop Wre Inserted to Stop Fgure 3 3 of 5
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. TE does not manufacture or market crmp-heght comparators. Detaled nformaton on obtanng and usng crmpheght comparators can be found n Instructon Sheet 408-7424. Proceed as follows: 1. Refer to Fgure 4 and select a wre (maxmum sze) for each crmp secton lsted. 2. Refer to Secton 5, CRIMPING PROCEDURE, and crmp the contact(s) accordngly. Screwdrver Ratchet Adjustment Wheel Lockscrew Fgure 5 Poston Pont on Center of Wre Barrel Opposte Modfed Anvl A 8. MAINTENANCE Ensure that the tool frame 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 tool handles closed to prevent objects from becomng lodged n the des, and store n a clean, dry area. WIRE SIZE AWG (Max) CRIMP SECTION (Wre Sze Markng) Fgure 4 CRIMP HEIGHT DIMENSION A (±0.05 [±.002]) 24 26-24 0.69 [.027] 18 22 0.79 [.031] 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. 2. Usng 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 counterclockwse to a hgher-numbered settng. If a looser crmp s requred, rotate the adjustment wheel clockwse to a lower-numbered settng. 4. Replace the lockscrew. 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. 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 TE 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 (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 11. REVISION SUMMARY Revsons to ths nstructon sheet nclude: Updated document to corporate requrements Corrected toolng nformaton n Secton 1, INTRODUCTION 4 of 5
Toolng Compatble wth De Assembly 90758-2 PRO-CRIMPER III Hand Tool Frame 354940-1 (Instructon Sheet 408-9930) SDE-SA 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) Electro-Hydraulc (BT 3500 Battery-Hydraulc) Hand Tool Kts 2031400-[ ] (Customer Manual 409-10095) Closed Head Assembly 2031460-1 (Instructon Sheet 408-10312) C -Head Assembly 2031450-1 (Instructon Sheet 408-10311) 5 of 5