APP 1309 Series Instruction Manual

1309 Series Crimp Tool
Instructions for Operation & Maintenance
NOTE: Use of non– Anderson Power Products (APP) crimp tools can affect UL & CSA approval. See website
for comprehensive application tooling data and the most current versions of documents, including this one.
Operating Procedure
1. Strip cable according to manufacturer’s specications.
2. Select the appropriate cavity for the contact being crimped per below chart.
3. Place contact on lower die with the contact wings or crimp barrel crease facing towards the
upper die (See Figure 1). Press the contact fully back into the locator until the wire stops or the
crimp barrel end is slightly inside the locator (See Figure 2).
4. Close tool carefully until jaws grip the contact.
5. Insert the properly stripped wire into the contact.
6. Holding the wire in place, close the tool past the ratchet release position and allow the jaws
to open. (A ratchet release lever is provided to allow removal of an incorrectly placed or
oversized contact).
7. Remove and inspect the crimp. There should not be any noticeable distortion in the angle of the
contact blade (See Figure 3).
8. Test by holding contact and pulling rmly on cable.
Figure 1
Figure 2
Figure 3
Upper die
Locator
Lower die
www.andersonpower.com
* No locator
** Anderson Power Products’ (APP) crimp recommendations are only recommendations and are based on the
specic wire used by APP in APP specic testing. Wire will vary by type, material, class, and manufacturer’s
rating & specications. APP crimp recommendations are intended to be used as a guide towards achieving UL
& CSA compliant crimps that enable the best performance of our connector systems. It is incumbent upon those
assembling / manufacturing with APP connectors to perform pull-out strength, mV drop, and other testing as
needed to ensure that crimps meet the customer specic requirements.
*** Should only be used with 2003G2-LPBK contacts.
Tooling Wire Size Pullout Values (lbs)**
Part Number Contacts AWG(mm²) (per UL standard 486A) Tool Cavities
1309G1 * 1202G1 #14-16 (2.5-1.5) 50-30 A
1203G1 #14-16 (2.5-1.5) 50-30 A
1309G2 1331 #12-16 (4.0-1.5) 70-30 30
1332 #16-20 (1.5-0.5) 30-13 15
262G1-LPBK #16-20 (1.5-0.5) 30-13 15
200G2L-LPBK #16-20 (1.5-0.5) 30-13 15
269G2-LPBK #16-20 (1.5-0.5) 30-13 15
1309G3 261G1-LPBK #12-14-16 (4.0-2.5-1.5) 70-50-30 A
261G2-LPBK #14-16 (2.5-1.5) 50-30 A
261G2-LPBK #10-14 (6.0-2.5) 80-70 B
269G1-LPBK #12-16 (4.0-1.5) 70-30 A
269G3-LPBK #10-14 (6.0-2.5) 80-50 A
1309G4* 1307 #6 (16.0) 100 Large
5900 #6 (16.0) 100 Large
5914 #10-12 (6.0-4.0) 80-70 Small
5915 #10-12 (6.0-4.0) 80-70 Large
5952 #8 (10.0) 90 Large
903G1 #6 (16.0) 100 Large
904G1 #10-12 (6.0-4.0) 80-70 Large
1339G2 #6 (16) 100 Large
1339G3 #10-12 (6-4) 80-70 Large
1339G5 #8 (10) 90 Large
1309G5 / G6 200G1L-LPBK 6mm, #10-14 80, 80-50 B
201G1H-LPBK 6mm, #10-14 80, 80-50 B
1309G6 1830G1-LPBK 6mm, #10-14 80, 80-50 B
1309G9 2003G1-LPBK #12 (4.0) 70 Large
2003G1-LPBK #14, 16, 18 (2.5 - 1.5) 50, 30, 20 Small
1309G10*** 2003G2-LPBK #12 (4.0) 70 Front
2003G2-LPBK #10 (60) 80 Rear
Nose up
Wire stop
OK
Nose down
End of locator
To far out from
locator
*Open Barrel Contact
Correct Not Correct
Closed Barrel Contact
Correct Not Correct
End of locator
To far out
from locator

HEADQUARTERS: Anderson Power Products®, 13 Pratts Junction Road, Sterling, MA 01564-2305 USA T:978-422-3600 F:978-422-0128 • EUROPE: Anderson Power Products® Ltd., Unit 3, Europa Court,
Europa Boulevard, Westbrook, Warrington, Cheshire, WA5 7TN United Kingdom T: [phone] F: [phone] • ASIA / PACIFIC: IDEAL Anderson Asia Pacic Ltd., Unit 922-928 Topsail
Plaza, 11 On Sum Street, Shatin N.T., Hong Kong T:+(852) 2636 0836 F:+(852) 2635 9036 • CHINA: IDEAL Anderson Technologies (Shenzhen) Ltd., Block A8 Tantou Western Industrial Park, Songgang Baoan
District, Shenzhen, PR. China 518105 T: +(86) 755 2768 2118 F: +(86) 755 2768 2218 • TAIWAN: IDEAL Anderson Asia Pacic Ltd., Taiwan Branch, 4F.-2, No.116, Dadun 20th St., Situn District, Taichung City
407, Taiwan (R.O.C.) T: +(886) 4 2310 6451 F:+(886) 4 2310 6460 • www.andersonpower.com
For additional updates see APP website All Data Subject To Change Without Notice 15882 , 1S6373 REV 14
Tool Maintenance
1. Maintenance and inspection should be performed regularly.
2. Verify the tool preload force to ensure it is properly calibrated. See “How to Adjust Tool Preload”.
3. Check the locator tension to ensure it is properly calibrated (Not applicable for 1309G4 or
1309G1). See “How to Adjust Locator Tension”.
4. Wipe tool clean with special emphasis on the crimping cavities.
5. Tool may be cleaned by immersing in a suitable commercial solvent or cleaner which does not
attack plastic material or paints.
6. Lubricate tool after cleaning using a light lm of medium weight oil on moving parts.
7. A light coating of lithium grease may be used on die cavities.
8. When not in use, keep handles closed, but without signicant force on the dies. Store in a
clean dry area.
How to Adjust Tool Preload
1. Measure current tool preload force by placing the end of one of the handles on a scale and
pushing the other grip until the ratchet releases. The amount of force should be measured 1 3/4
inches from handle end as shown (See Figure 4).
2. To adjust tool to obtain proper force values, open the handles and remove the cam locking
screw with the hex key wrench (See Figure 5).
3. Rotate the cam clockwise to increase handle load or counterclockwise to decrease handle load.
4. Position odd numbers on the cam in the locking screw hole adjacent to the letter “L” and even
numbers adjacent to the letter “T”.
5. Lock the cam at the desired handle load setting by inserting the locking screw and remeasure the force.
Continue adjustment if necessary.
Proper Force Values: 1309G1-1309G6 (25 lbs. min) 1309G9-10 (55 lbs. min)
How to Adjust Locator Tension
1. Using 9 mm or 11/32” wrench, tighten the nut on the locator stud until it bottoms out
(do not over torque or the locator may crack).
2. LOOSEN THE NUT ONE COMPLETE TURN. This is required for correct tool operation.
NOTE: Distortion of the contacts can occur if the locator is not adjusted properly so that it is
allowed to move. There should not be any noticeable distortion in the angle of the contact blade
after crimping (See Figure 3).
Replacing Dies and Locators
Disassemble
1. Inspect tool frame to ensure good mechanical condition. If not in good condition then
replace entire tool.
2. Remove the nut, wavy washer and locator.
3. Unscrew the top and bottom die screws.
4. Remove the dies from the frame. The tool can now be assembled with a different dieset
conguration.
Reassemble
1. Assemble the desired die in the top position with the supplied short screw.
(See Figure 7)
2. Place the bottom anvil die in the frame. (See Figure 7)
3. Tighten the screws until they bottom on the frame and loosen ½ turn.
4. Place the locator, wavy washer and nut on the screw; in that order.
(See Figure 6 & Figure 8)
5. Follow steps under “How to Adjust Locator Tension”.
7. Follow steps under “How to Adjust Tool Preload”. If tool is no longer able to provide “Proper
Force Values” then replace the entire tool.
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
1309 Series Crimp Tool
Instructions for Operation & Maintenance
Page 2
Load applied
All tools except 1309G9-10: Apply torque as shown
until ratchet releases. The force at a point 1-3/4”
from handle end should be 25 pounds minimum for
most crimping situations For the 1309G9-10 set at 55
pounds minimum.
1 3/4 “ ±1/4”
Locator and nose
end of hand tool
Eccentric stud
Cam Locking screw
Small cavity
Large cavity
Tighten bottom out
and then loosen one
complete turn
Wavy Washer
in place
Top Die,
Forming Die
Bottom Die,
Anvil
Short Screw