Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet

PRO- CRIMPER* III Hand

Crimping Tool Assembly 90652- 1 408--9853

LOC B

1of 6

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1--800--722--1111

PRODUCT INFORMATION 1--800--522--6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

17 AUG 09 Rev Cwith Die Assembly 90652- 2

PROPER USE GUIDELINES

Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume

applications. A wide selection of powered application equipment for extended--use, production operations is available.

The PRO--CRIMPER III Hand Crimping Tool is a “Commercial” grade tool

and is designed primarily for field installation, repair, maintenance work, or

prototyping in industrial, commercial, or institutional applications. Product

crimped with this tool will meet the crimp height requirement for hand tools in

the appropriate 114 series specification, but may not comply with other feature

parameters of the specification. Tyco Electronics offers a variety of tools to

satisfy your performance requirements. For additional information, contact the

Technical Assistance Center at 1--800--722--1111.

Stationary Jaw

Back of Tool

(Wire side)

Pivot Pin

PRO--CRIMPER III Hand

Crimping Tool Frame

354940--1 (408--9930)

Stationary

Handle

Moving

Handle

Locator

Assembly

(Supplied with

Die Assembly)

Font of Tool

(Locator Side)

Die

Assembly

Moving Jaw

Ratchet Adjustment Wheel

Wire

TE Die Assembly Locator Assembly{Contact Family}Size

(AWG)

Insul Dia

(mm [In.])

Strip Length

(mm [In.])

20 1.60 to 2.11

[.063 to .083]

90652--2 58515--1

Multilock

.040 Series

Contacts

18 1.80 to 2.31

[.071 to .091]

3.99 to 4.50

[.175 to .177]

22 1.40 to 1.90

[.055 to .075]

{Supplied with die assembly. Also available separately. }Contact the Tooling Assistance Center or Product Information (below) for specific contact part numbers.

Figure 1

1. INTRODUCTION

PRO--CRIMPER III Hand Crimping Tool

Assembly 90653--1 consists of Die Assembly

90653--2 and PRO--CRIMPER III Hand Crimping Tool

Frame 354940--1. The die assembly consists of

crimping dies and a locator assembly.

Read these instructions thoroughly before crimping

any contacts.

Dimensions on this sheet are in millimeters [with

inch equivalents provided in brackets]. Figures

and illustrations are for identification only and are

not drawn to scale.

Reasons for reissue are provided in Section 11,

REVISION SUMMARY.

NOTE

408- 9853

PRO- CRIMPER III Hand Crimping Tool Assembly 90652- 1

Rev C2 of 6 Tyco Electronics Corporation

Figure 2

Nut

Chamfer

Wire Crimper

Offset

Wire Anvil Insulation Anvil Chamfer

Locator Assembly Tool Frame

Die Retaining

Pins

Die Retaining Screws

Insulation

Crimper

2. DESCRIPTION (Figures 1 and 2)

The tool features a tool frame with a stationary jaw

and handle, a moving jaw, a moving handle, and an

adjustable ratchet that ensures full contact crimping.

The tool frame holds a die assembly with two

crimping sections.

The die assembly features a wire anvil, an insulation

anvil, a wire crimper, and an insulation crimper.

Attached to the outside of the frame is a locator

assembly, which contains a locator, a spring retainer,

and a contact support.

Die retaining pins and die retaining screws are used

to position and secure the dies in the tool frame. A

nut is used on the upper die retaining screw to hold

the locator assembly in place.

3. INSTALLATION AND REMOVAL OF DIE SET

AND LOCATOR ASSEMBLY (Figure 2)

1. Open the tool handles and remove the two die

retaining screws from the tool jaws

2. Place the wire anvil and insulation anvil so that

their chamfered sides and their marked surfaces

face outward, when mounted in the moving jaw of

the tool frame.

3. Insert the two die retaining pins.

4. Insert the short die retaining screw through the

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.

5. Place the wire crimper and insulation crimper so

that their chamfered sides and their marked

surfaces face outward, when mounted in the

stationary jaw of the tool frame.

6. Insert the two die retaining pins.

7. Insert the long die retaining screw through the

jaw and through both crimper dies, and tighten the

screw just enough to hold the dies in place. Do not

tighten the screw completely at this time.

8. Carefully close the tool handles, making sure

that the anvils and crimpers align properly.

Continue closing the tool handles until the ratchet

in the tool frame has engaged sufficiently to hold

the anvils and crimpers in place, then tighten both

die retaining screws.

9. Place the locator assembly over the end of the

long screw, and position the locator assembly

against the side of the tool jaw.

10. Place the nut onto the end of the long screw

and tighten the nut enough to hold the locator

assembly in place, while still allowing the locator to

slide up and down.

11. To disassemble, close the tool handles until the

ratchet releases, remove the nut, the locator

assembly, the two die retaining screws, and the

four die retaining pins, and slide the anvils and

crimpers out of the tool jaws.

408- 9853

PRO- CRIMPER III Hand Crimping Tool Assembly 90652- 1

3of 6Rev CTyco Electronics Corporation

4. CONTACT SUPPORT ADJUSTMENT (Figure 3)

The contact support is preset prior to shipment,

but minor adjustment may be necessary.

1. Make a sample crimp and determine if the

contact is straight, bending upward, or bending

downward.

2. If adjustment is required, loosen the screw that

holds the contact support onto the locator

assembly.

The ratchet has detents that create audible clicks

as the tool handles are closed.

3. Place a contact with wire into the proper nest

and close the tool handles until the ratchet reaches

the sixth click, or until the contact support touches

the contact.

4. Slightly loosen the nut that holds the locator

assembly onto the tool frame

5. Move the contact support as required to

eliminate the bending of the contact.

6. Tighten the nut and close the handles until the

ratchet releases.

7. Remove and inspect the contact.

8. Make another sample crimp. If the contact is

straight, tighten the contact support screw. If the

contact is still being bent during crimping, repeat

the adjustment procedure.

5. CRIMPING PROCEDURE

This tool is provided with a crimp adjustment

feature. Initially, the crimp height should be

verified as specified in Figure 4. Refer to

Section 6, CRIMP HEIGHT INSPECTION , and

Section 7, RATCHET (Crimp Height)

ADJUSTMENT, to verify crimp height before

using the tool to crimp desired contacts and wire

sizes.

Refer to the table in Figure 1 and select wire of the

specified size and insulation diameter. Strip the wire

to the length indicated in Figure 1, taking care not to

nick or cut wire strands. Select an applicable contact

and identify the appropriate crimp section according

to the wire size markings on the tool. Refer to

Figure 3 and proceed as follows:

1. Hold the tool so that the back (wire side) is

facing you. Squeeze tool handles together and

allow them to open fully.

2. Holding the contact by the mating end, insert the

contact — insulation barrel first — through the front

of the tool and into the appropriate crimp section.

3. Position the contact so that the mating end of

the contact is on the locator side of the tool, and so

that the open “U” of the wire and insulation barrels

face the top of the tool. Place the contact up into

the nest so that the movable locator drops into the

slot in the contact. Refer to Figure 3. Butt the front

end of the wire barrel against the movable locator.

Figure 3

Contact

Support

Adjustment

Screw for

Contact

Support

Locator

Back of Tool

(Wire Side)

Wire

Contact

(Typ)

Locator in

Wire Stop

Slot

Wire Inserted

to Stop

Strip

Length

NOTE

408- 9853

PRO- CRIMPER III Hand Crimping Tool Assembly 90652- 1

Rev C4 of 6 Tyco Electronics Corporation

Make sure that both sides of the insulation barrel

are started evenly into the crimping section. Do

NOT attempt to crimp an improperly positioned

contact.

4. Hold the contact in position and squeeze the

tool handles together until ratchet engages

sufficiently to hold the contact in position. Do NOT

deform insulation barrel or wire barrel.

5. Insert stripped wire into contact insulation and

wire barrels until it is butted against the wire stop,

as shown in Figure 3.

6. Holding the wire in place, squeeze tool handles

together until ratchet releases. Allow tool handles

to open and remove crimped contact.

The crimped contact may stick in the crimping

area, but the contact can be easily removed by

pushing downward on the top of the locator (see

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. CRIMP HEIGHT INSPECTION

Crimp height inspection is performed through the use

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

found in instruction sheet 408--7424.

Proceed as follows:

1. Refer to Figure 4 and select a wire (maximum

size) for each crimp section listed.

2. Refer to Section 5, CRIMPING PROCEDURE,

and crimp the contact(s) accordingly.

3. Using a crimp height comparator, measure the

wire barrel crimp height as shown in Figure 4. If the

crimp height conforms to that shown in the table,

the tool is considered dimensionally correct. If not,

the tool must be adjusted. Refer to Section 7,

RATCHET (Crimp Height) ADJUSTMENT.

7. RATCHET (Crimp Height) ADJUSTMENT

1. Remove the lockscrew from the ratchet

adjustment wheel.

2. With a screwdriver, adjust the ratchet wheel

from the locator side of the tool.

Position Point

on Center of

Wire Barrel

Opposite

Seam

“A”

Modified Anvil

Wire Size Crim

Section Crimp Height

(

)

AWG(Max)

(Wire Size Marking) Dimension (A

)

Tolerance (+.)

20 20 .927 + .051

[.036 + .0020]

18 18 1.041 + .051

[.0410 + .0020]

22 22 .851 + .051

[.0335 + .0020]

Figure 4

3. Observe the ratchet adjustment wheel. If a

tighter crimp is required, rotate the adjustment

wheel COUNTERCLOCKWISE to a

higher--numbered setting. If a looser crimp is

required, rotate the adjustment wheel

CLOCKWISE to a lower--numbered setting.

4. Replace the lockscrew.

5. Make a sample crimp and measure the crimp

height. If the dimension is acceptable, replace and

secure the lockscrew. If the dimension is

unacceptable, continue to adjust the ratchet, and

again measure a sample crimp.

Figure 5

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew

(Typ)

CAUTION

NOTE

408- 9853

PRO- CRIMPER III Hand Crimping Tool Assembly 90652- 1

5of 6Rev CTyco Electronics Corporation

8. MAINTENANCE

Ensure that the tool and dies are clean by wiping

them with a clean, soft cloth. Remove any debris with

a clean, soft brush. Do not use objects that could

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.

9. VISUAL INSPECTION

The crimping dies should be inspected on a regular

basis to ensure that they have not become worn or

damaged. Inspect the crimp sections for flattened,

chipped, worn, or broken areas. If damage or

abnormal wear is evident, the tool must be replaced.

See Section 10, REPLACEMENT.

10. REPLACEMENT

Customer--replaceable parts are shown in Figure 1.

Available separately, PRO--CRIMPER III Hand

Crimping Tool Repair Kit 679221--1 includes a

replacement nut and a variety of pins, rings, screws,

and springs.

If the dies are damaged or worn excessively, they

must be replaced.

Order the repair kit and replaceable parts through

your Tyco Electronics representative, or call

1--800--526--5142, or send a facsimile of your

purchase order to 1--717--986--7605, or write to:

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS

PO BOX 3608

HARRISBURG PA 17105--3608

11. REVISION SUMMARY

Revisions to this instruction sheet include:

SChanged PRO--CRIMPER II Hand Tool to

PRO--CRIMPER III Hand Tool;

SAdded back page (tooling using die assembly

90652--2);

SAdded TE logo; and

SUpdated format to current corporate

requirements.

408- 9853

PRO- CRIMPER III Hand Crimping Tool Assembly 90652- 1

Rev C6 of 6 Tyco Electronics Corporation

PRO-CRIMPER III Hand Tool 354940- 1

(Instruction Sheet 408-9930)

SDE PEW- 12 Hand Tool 9-1478240-0

(Instruction Sheet 408-8851)

SDE Bench Terminator 1490076- 2

(Customer Manual 409-10052)

626 Adapter 679304-1

(Instruction Sheet 408-4070)

Battery Tool (Shouldered Die) 1725837-1, - 2

(Customer Manual 409-10053)

Battery Tool (Pin Die) 1213890- 1, - 2

(Customer Manual 409-10065)

Die Assembly 90652- 2 Can Be Used In the Following Tools:

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