InstructionSheet PRO-CRIMPER*IIIHandCrimping 408--9883 ToolAssembly90546-1with DieAssembly90546-2 16Mar11 RevD PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awideselectionofpoweredapplicationequipmentforextended--use,productionoperationsisavailable. Locator Assembly StationaryJaw (Suppliedwith BackofTool DieAssembly) (Wireside) FontofTool (LocatorSide) PivotPin Die PRO--CRIMPERIIIHand Assembly CrimpingToolFrame 354940--1 (408--9930) MovingJaw RatchetAdjustmentWheel Stationary ThePRO--CRIMPERIIIHandCrimpingToolisa“Commercial”gradetool Handle andisdesignedprimarilyforfieldinstallation,repair,maintenancework,or prototypinginindustrial,commercial,orinstitutionalapplications.Product crimpedwiththistoolwillmeetthecrimpheightrequirementforhandtoolsin Moving theappropriate114seriesspecification,butmaynotcomplywithotherfeature Handle parametersofthespecification.TE offersavarietyoftoolstosatisfyyour performancerequirements.Foradditionalinformation,contacttheTooling AssistanceCenterat1--800--722--1111. Wire TEDieAssembly LocatorAssembly{ ContactFamily} Size InsulDia StripLength (AWG) (mm[In.]) (mm[In.]) Universal 20--18 11..5522ttoo33..3300 33..9966ttoo44..7755 9900554466----22 5588551155----11 MMAATTEE----NN----LLOOKK** [.060to.130] [.156to.187] Contacts 16--14 { Suppliedwithdieassembly. Alsoavailableseparately. } ContacttheToolingAssistanceCenterorProductInformation(below)forspecificcontactpart numbers. Figure1 1. INTRODUCTION ReasonsforreissueareprovidedinSection11, REVISIONSUMMARY. PRO--CRIMPERIIIHandCrimpingTool Assembly90546--1consistsofDieAssembly 90546--2andPRO--CRIMPERIIIHandCrimpingTool Frame354940--1.Thedieassemblyconsistsof 2. DESCRIPTION(Figures1and2) crimpingdiesandalocatorassembly. Thetoolfeaturesatoolframewithastationaryjaw Readtheseinstructionsthoroughlybeforecrimping andhandle,amovingjaw,amovinghandle,andan anycontacts. adjustableratchetthatensuresfullcontactcrimping. Thetoolframeholdsadieassemblywithtwo NOTE Dimensionsonthissheetareinmillimeters[with crimpingsections. inchequivalentsprovidedinbrackets].Figures i andillustrationsareforidentificationonlyandare Thedieassemblyfeaturesawireanvil,aninsulation notdrawntoscale. anvil,awirecrimper,andaninsulationcrimper. E2011TycoElectronicsCorporation,aTEConnectivityLtd.Company TOOLINGASSISTANCECENTER1--800--722--1111 Thiscontrolleddocumentissubjecttochange. 1of6 AllRightsReserved PRODUCTINFORMATION1--800--522--6752 ForlatestrevisionandRegionalCustomerService, TElogoisatrademark. visitourwebsiteatwww.te.com LOCB *Trademark. Otherproductnames,logos,orcompanynamesmightbetrademarksoftheirrespectiveowners.

408-9883 Nut Locator Assembly ToolFrame Locator Insulation DieRetaining Crimper Chamfer Pins WireCrimper Offset WireAnvil Chamfer Insulation DieRetaining Anvil Screws Figure2 Attachedtotheoutsideoftheframeisalocator screwjustenoughtoholdthediesinplace.Donot assembly,whichcontainsalocator,aspringretainer, tightenthescrewcompletelyatthistime. andacontactsupport. 8. Carefullyclosethetoolhandles,makingsure Dieretainingpinsanddieretainingscrewsareused thattheanvilsandcrimpersalignproperly. topositionandsecurethediesinthetoolframe.A Continueclosingthetoolhandlesuntiltheratchet nutisusedontheupperdieretainingscrewtohold inthetoolframehasengagedsufficientlytohold thelocatorassemblyinplace. theanvilsandcrimpersinplace,thentightenboth dieretainingscrews. 3. INSTALLATIONANDREMOVALOFDIESET 9. Placethelocatorassemblyovertheendofthe ANDLOCATORASSEMBLY(Figure2) longscrew,andpositionthelocatorassembly againstthesideofthetooljaw. 1. Openthetoolhandlesandremovethetwodie retainingscrewsfromthetooljaws. 10. Placethenutontotheendofthelongscrew andtightenthenutenoughtoholdthelocator 2. Placethewireanvilandinsulationanvilsothat assemblyinplace,whilestillallowingthelocatorto theirchamferedsidesandtheirmarkedsurfaces slideupanddown. faceoutward,whenmountedinthemovingjawof thetoolframe. 11. Todisassemble,closethetoolhandlesuntilthe ratchetreleases,removethenut,thelocator 3. Insertthetwodieretainingpins. assembly,thetwodieretainingscrews,andthe fourdieretainingpins,andslidetheanvilsand 4. Inserttheshortdieretainingscrewthroughthe crimpersoutofthetooljaws. jawandthroughbothanvildies,andtightenthe screwjustenoughtoholdthediesinplace.Donot tightenthescrewcompletelyatthistime. 4. CONTACTSUPPORTADJUSTMENT(Figure3) 5. Placethewirecrimperandinsulationcrimperso NOTE Thecontactsupportispresetpriortoshipment, thattheirchamferedsidesandtheirmarked butminoradjustmentmaybenecessary. surfacesfaceoutward,whenmountedinthe i stationaryjawofthetoolframe. 6. Insertthetwodieretainingpins. 1. Makeasamplecrimpanddetermineifthe 7. Insertthelongdieretainingscrewthroughthe contactisstraight,bendingupward,orbending jawandthroughbothcrimperdies,andtightenthe downward. 2of6 RevD

408-9883 2. Ifadjustmentisrequired,loosenthescrewthat 5. CRIMPINGPROCEDURE holdsthecontactsupportontothelocator assembly. NOTE Thistoolisprovidedwithacrimpadjustment feature.Initially,thecrimpheightshouldbe i verifiedasspecifiedinFigure4.Referto NOTE Theratchethasdetentsthatcreateaudibleclicks Section6,CRIMPHEIGHTINSPECTION,and asthetoolhandlesareclosed. Section7,RATCHET(CrimpHeight) i ADJUSTMENT,toverifycrimpheightbefore usingthetooltocrimpdesiredcontactsandwire sizes. 3. Placeacontactwithwireintothepropernest RefertothetableinFigure1andselectwireofthe andclosethetoolhandlesuntiltheratchetreaches specifiedsizeandinsulationdiameter.Stripthewire thesixthclick,oruntilthecontactsupporttouches tothelengthindicatedinFigure1,takingcarenotto thecontact. nickorcutwirestrands.Selectanapplicablecontact andidentifytheappropriatecrimpsectionaccording tothewiresizemarkingsonthetool.Referto 4. Slightlyloosenthenutthatholdsthelocator Figure3andproceedasfollows: assemblyontothetoolframe. 1. Holdthetoolsothattheback(wireside)is 5. Movethecontactsupportasrequiredto facingyou.Squeezetoolhandlestogetherand eliminatethebendingofthecontact allowthemtoopenfully 2. Holdingthecontactbythematingend,insertthe 6. Tightenthenutandclosethehandlesuntilthe contact—insulationbarrelfirst—throughthefront ratchetreleases. ofthetoolandintotheappropriatecrimpsection. 3. Positionthecontactsothatthematingendof 7. Removeandinspectthecontact. thecontactisonthelocatorsideofthetool,andso thattheopen“U”ofthewireandinsulationbarrels 8. Makeanothersamplecrimp.Ifthecontactis facethetopofthetool.Placethecontactupinto straight,tightenthecontactsupportscrew.Ifthe thenestsothatthemovablelocatordropsintothe contactisstillbeingbentduringcrimping,repeat slotinthecontact.RefertoFigure3.Buttthefront theadjustmentprocedure. endofthewirebarrelagainstthemovablelocator. Locator Contact Support BackofTool Adjustment (WireSide Screwfor Contact Support Contact Strip (Typ) Length Wire Locatorin Wire WireStop Inserted Slot toStop Figure3 RevD 3of6

408-9883 CAUTION Makesurethatbothsidesoftheinsulationbarrel Proceedasfollows: arestartedevenlyintothecrimpingsection.Do ! NOTattempttocrimpanimproperlypositioned 1. RefertoFigure4andselectawire(maximum contact. size)foreachcrimpsectionlisted. 4. Holdthecontactinpositionandsqueezethe 2. RefertoSection5,CRIMPINGPROCEDURE, toolhandlestogetheruntilratchetengages andcrimpthecontact(s)accordingly. sufficientlytoholdthecontactinposition.DoNOT deforminsulationbarrelorwirebarrel. 3. Usingacrimpheightcomparator,measurethe wirebarrelcrimpheightasshowninFigure4.Ifthe 5. Insertstrippedwireintocontactinsulationand crimpheightconformstothatshowninthetable, wirebarrelsuntilitisbuttedagainstthewirestop, thetoolisconsidereddimensionallycorrect.Ifnot, asshowninFigure3. thetoolmustbeadjusted.RefertoSection7, RATCHET(CrimpHeight)ADJUSTMENT. 6. Holdingthewireinplace,squeezetoolhandles togetheruntilratchetreleases.Allowtoolhandles toopenandremovecrimpedcontact. 7. RATCHET(CrimpHeight)ADJUSTMENT(Figure5) NOTE Thecrimpedcontactmaystickinthecrimping 1. Removethelockscrewfromtheratchet area,butthecontactcanbeeasilyremovedby adjustmentwheel. i pushingdownwardonthetopofthelocator(see Figure3). 2. Withascrewdriver,adjusttheratchetwheel fromthelocatorsideofthetool. 7. Checkthecontact’scrimpheightasdescribedin Section6,CRIMPHEIGHTINSPECTION.If 3. Observetheratchetadjustmentwheel.Ifa necessary,adjustthecrimpheightasdescribedin tightercrimpisrequired,rotatetheadjustment Section7,RATCHET(CrimpHeight) wheelCOUNTERCLOCKWISEtoa ADJUSTMENT. higher--numberedsetting.Ifaloosercrimpis required,rotatetheadjustmentwheel CLOCKWISEtoalower--numberedsetting. 6. CRIMPHEIGHTINSPECTION 4. Replacethelockscrew. Crimpheightinspectionisperformedthroughtheuse ofamicrometerwithamodifiedanvil,commonly 5. Makeasamplecrimpandmeasurethecrimp referredtoasacrimp--heightcomparator.TEdoes height.Ifthedimensionisacceptable,replaceand notmanufactureormarketcrimp--heightcomparators. securethelockscrew.Ifthedimensionis Detailedinformationonobtainingandusing unacceptable,continuetoadjusttheratchet,and crimp--heightcomparatorscanbefoundininstruction againmeasureasamplecrimp. sheet408--7424. PositionPoint Screwdriver onCenterof WireBarrel Opposite Seam ModifiedAnvil “A” CrimpHeight Ratchet WWiirreeSSiizzee CCrriimmppSSeeccttiioonn DDiimmAAaanndd Adjustment AWG(Max) (WireSizeMarking) Tolerance(+) Wheel 18 20--18 1.27.05 [.050.002] 14 16--14 1.60.05 Lockscrew [.063.002] (Typ) Figure4 Figure5 4of6 RevD

408-9883 8. MAINTENANCE sendafacsimileofyourpurchaseorderto 1--717--986--7605,orwriteto: Ensurethatthetoolanddiesarecleanbywiping themwithaclean,softcloth.Removeanydebriswith CUSTOMERSERVICE(38--35) aclean,softbrush.Donotuseobjectsthatcould TYCOELECTRONICS damagethetool.Whennotinuse,keephandles POBOX3608 closedtopreventobjectsfrombecominglodgedin HARRISBURGPA 17105--3608 thecrimpingdies,andstoreinaclean,dryarea. 9. VISUALINSPECTION 11.REVISIONSUMMARY Thecrimpingdiesshouldbeinspectedonaregular Revisionstothisinstructionsheetinclude: basistoensurethattheyhavenotbecomewornor damaged.Inspectthecrimpsectionsforflattened, S Updateddocumenttocorporaterequirements. chipped,worn,orbrokenareas.Ifdamageor abnormalwearisevident,thetoolmustbereplaced. SeeSection10,REPLACEMENT. 10. REPLACEMENT Customer--replaceablepartsareshowninFigure1. Availableseparately,PRO--CRIMPERIIIHand CrimpingtoolRepairKit679221--1includesa replacementnutandavarietyofpins,rings,screws, andsprings. Ifthediesaredamagedorwornexcessively,they mustbereplaced. Ordertherepairkitandreplaceablepartsthrough yourTErepresentative,orcall1--800--526--5142,or RevD 5of6

408-9883 DieAssembly90546-2CanBeUsedIntheFollowingTools: PRO-CRIMPERIIIHandTool354940-1 SDEPEW-12HandTool9-1478240-0 (InstructionSheet408-9930) (InstructionSheet408-8851) SDEBenchTerminator1490076-2 626Adapter679304-1 (CustomerManual409-10052) (InstructionSheet408-4070) BatteryTool(ShoulderedDie)1725837-1, -2 BatteryTool(PinDie)1213890-1, -2 (CustomerManual409-10053) (CustomerManual409-10065) 6of6 RevD

Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: T E Connectivity: 90546-1 90546-2