HARTING 09 99 000 0990 User manual

HARTING
Battery Crimping Tool 09 99 000 0990
Instruction Manual /
Akku-Crimpwerkzeug 09 99 000 0990
Betriebsanleitung

HARTING Electric GmbH & Co. KG
2
HARTING Battery crimping tool 09 99 000 0990
© 2021, status of September 2021 (Version 1.0)
HARTING Electric GmbH & Co. KG, Espelkamp, Germany
Author: HARTING, Publisher: HARTING
All rights are reserved, including those of the translation.
No part of this document may be reproduced in any form (print, photocopy, micro󰘰lm or by
any other method), processed, duplicated or distributed by means of electronic systems
without the written permission of HARTING Electric GmbH & Co. KG, Espelkamp, Germany.
Subject to alterations without notice.
© 2021, Stand September 2021 (Version 1.0)
HARTING Electric GmbH & Co. KG, Espelkamp
Autor: HARTING, Herausgeber: HARTING
Alle Rechte, auch der Übersetzung, vorbehalten.
Kein Teil dieses Dokuments darf ohne schriftliche Zustimmung der HARTING Electric GmbH
& Co. KG, Espelkamp, in irgendeiner Form (Druck, Fotokopie, Mikrolm oder einem anderen
Verfahren) reproduziert oder unter Verwendung elektronischer Systeme verarbeitet, verviel-
fältigt oder verarbeitet werden. Änderungen vorbehalten.

3
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
HARTING Battery crimping tool 09 99 000 0990
EN Table of contents
1. Crimp connection.......................................4
1.1 Extraction force of the stranded
wire..................................................4
1.2 Tools for crimping ...........................4
2. Product information..................................5
2.1 Overview of crimping tool ...............5
2.2 Scope of delivery.............................5
3. About this document ................................6
3.1 Target groups ..................................6
3.2 Explanation of the symbols and
formats used....................................6
4. General information and safety................7
4.1 Intended use....................................7
4.2 Non-intended use, how to avoid......7
4.3 Changes, up-to-dateness, validity ...8
4.4 General safety instructions..............9
4.5 Care instructions............................11
4.6 Disposal.........................................11
5. Technical data.......................................12
6. Components...........................................12
7. Suitable contacts and accessories.........13
8. Set-up and commissioning.....................14
8.1 Setting up the battery
crimping tool ..................................14
8.1.1 Installation / exchange of
battery ......................................14
8.1.2 Insertion of the crimping die .....16
8.2 Crimping ........................................18
8.3 Removing the holder .....................22
9. Battery and charger................................22
9.1 Charging the battery......................22
9.2 Charger status display...................22

HARTING Electric GmbH & Co. KG
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HARTING Battery crimping tool 09 99 000 0990
By reshaping the contact point, crimping
tools produce a mechanically 󰘰rm crimp of
the wire strands in the contact’s connection
zone. This reforming is caused by pressu-
re exerted by the pliers. The positioner en-
sures that the terminal area of the contact is
correctly placed in the crimping die.
A perfectly crimped connection is both gas-
tight and corrosion-resistant. The required
retention force between the stranded wire
and the contact must be established and
the contact resistance must be constant.
Crimping tools have a ratchet mechanism
that ensures only high quality crimp connec-
tions are produced. Only after the crimping
process is completely 󰘰nished does the tool
head open (automatically).
1. Crimp termination
The key criterion for a high-quality crimped
connection is the retention force achieved
by the stranded wire within the contact’s
connecting element. Table 1 lists the ex-
traction forces in relationship to the wire
cross-sections, according to DIN EN 60352-
2:2006. Crimped connections which have
been properly produced using HARTING
crimping tools comply with these required
extraction forces.
1.2 Tools for crimping technology
1.1 Pull-out forces for stranded wires
Figure 1: Micrograph of a HARTING hexa-
gonal crimp
Table 1: Pull-out forces for crimped con-
nections (DIN EN 60 352-2: 2006)
Wire gauge/cross
section
Pull out
force
mm² AWG N
0.05 30 6
0.08 28 11
0.12 26 15
0.14 18
0.22 24 28
0.25 32
0.32 22 40
0.50 20 60
0.75 85
0.82 18 90
1.0 108
1.3 16 135
1.5 150
2.1 14 200
2.5 230
3.3 12 275
4.0 310
5.3 10 355
6.0 360
8.4 8 370
10.0 380

5
Release lever
Battery
Load level display
Crimping die Holding ring
Product information
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
2. Product information
2.1 Overview crimping tool
This chapter describes the battery crimping
tool along with its connected accessories.
The battery, its insertion and exchange, are
highlighted in the following subchapter (2.3)
Locator
2.2 Included in delivery
Figure 2: HARTING Battery crimping tool
09 99 000 0990
The HARTING Battery crimping tool
09 99 000 0990 is a hand tool for the bat-
tery or motor-supported crimping of Han D
®
,
Han E
®
and Han
®
C contact types, which have
a conductor cross-section of up to 4 mm².
Table 2: Components of HARTING Battery
crimping tool (set)
Part no. Identication
0999 000 0990 Battery crimping
tool (Set)
0999 000 0832 Crimping tool including
set of dies
0999 000 0994 Rechargeable battery
Battery charger
0999 000 0991 Locator Han D®
0999 000 0992 Locator Han E®
0999 000 0993 Locator Han® C

HARTING Electric GmbH & Co. KG
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HARTING Battery crimping tool 09 99 000 0990
CAUTION!
Caution!
Caution identifies a situation where minor or moderate inju-
ries could result if the danger is not avoided.
WARNING!
Warning!
Warning identifies a situation where death or serious injury
could result if the danger is not avoided.
DANGER!
Danger!
Danger identifies a situation where death or serious injury
will result if the danger is not avoided.
3. About this document
3.1 Target groups
The instruction manual is intended for:
• operators and users who are using the
crimping tool to crimp contacts for indus-
trial connectors.
• trained technicians who are planning to
crimp contacts for industrial connectors,
set up the relevant work places, instruct
operators, and want to learn about this
crimping tool.
3.2 Explanation of symbols and formats used
This document uses the following special
symbols and formats:
The operating instructions of this manual de-
scribe the commissioning, operation, mainte-
nance and disposal of the HARTING Battery
crimping tool 09 99 000 0990. The tool should
only be used for processing solid, turned
(machined) crimp contacts from the Han
®
C,
Han D
®
and Han E
®
series.

7
General information and safety
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
A ► marks a feedback or control option. This
information can help you to successfully
complete an installation step.
Text highlighted in blue indicates references
to other chapters or URLs from other web-
sites.
This crimping tool should be used exclusively
for producing crimped connections, which
connect stranded wires with contacts from
the Han
®
C, Han D
®
and Han E
®
Han series
(for details of conductor cross-sections that
can be processed, ⇨ Chapt. 8, p. 14).
Combined with crimping die and locator, this
crimping tool must be used exclusively in the
manner and for the purposes described in
this document. All other uses of the crimping
tool are not intended and exclude liability of
the manufacturer and the supplier for any re-
sulting damage; the operating company alo-
ne bears the risk.
4. General information and safety
This chapter de󰘰nes the proper and inten-
ded usage for the crimping tool and gives
general safety instructions. This information
must be observed during the tool’s commis-
sioning (⇨ Chapter 7, p. 13), operation and
maintenance.
4.1 Proper and intended use
4.2 Non-intended use, how to avoid
The most critical potential for misuse is
when the operator reaches near the repla-
ceable crimping die while the crimping tool
is running.
Caution: Danger of being crushed!
Avoid:
• To minimise the risk, switch o󰘯 the batte-
ry crimping tool before reaching into the
area of the crimping die.
• Only use components and accessories that
are speci󰘰ed as suitable in this document.
NOTICE
Notice
Notice indicates that there is a risk of damage to property.
Ignoring such notes can lead to a worsening of the operating
conditions.

HARTING Electric GmbH & Co. KG
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HARTING Battery crimping tool 09 99 000 0990
•Never carry out unauthorised conver-
sions, modications, repairs or misu-
se of the crimping tool, with the excep-
tion of the crimping die conversions
described in Chapt. 8.1.2, p. 16. Un-
authorised modications exclude the
manufacturer’s or supplier’s liability
for any resulting damage.
4.3 Changes, timeliness, validity
Changes
The instructions of this manual are subject
to revision but are not maintained by an
updating service. After deliverance, it is the
responsibility of the operator to update the
instructions with any available supplements
provided by HARTING or the operator.
With regard to the technical data, pictures
and other information on the crimping tool,
HARTING reserves the right to introduce
changes and improvements (e.g. to re󰘱ect
the technical progress) without prior notice.
Timeliness
The laws, regulations, directives, techni-
cal rules as well as the derived statements
found in these operation instructions all
correspond to the most current informati-
on available during preparation (as of July
2021).
It is the responsibility of the operating com-
pany to pursue the development of relevant
regulations. When requirements become
stricter, the operating company is also
responsible for ensuring that the corres-
ponding changes to the crimping tool are
implemented.
The contents of these operating instruc-
tions are not part of an earlier agreement,
commitment or legal relationship; they do
not change any existing legal relationship.
HARTING’s obligations arise exclusively
from the respective supply contract for the
product (including the sole valid warranty
agreement contained in the supply con-
tract).
Validity
This instruction manual is intended for the
HARTING Battery crimping tool along with
the named accessories. Please specify the
crimping tool number, serial number and
tool type (refer to name plate) when making
further inquiries and ordering spare parts.
This instruction manual only provides infor-
mation about the crimping tool and compo-
nents that are included in the delivery. You
may obtain further information on matters
not described in this document directly from
the HARTING Electric GmbH & Co. KG.
These operating instructions have been pre-
pared in accordance with the EC Directive
2006/42/EC and the relevant European har-
monised standards. Included instructions
pertaining to occupational safety may not
match the harmonised German statutory
accident prevention regulations (DGUV) or
the technical regulations and DIN standards
listed in the Annex to the Occupational
Safety Act.

9
General information and safety
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
The customer/operating company is re-
sponsible for understanding the listed rules
(laws, regulations and guidelines) and for
using them to ensure safe handling and
initial commissioning. They must also take
into account the relevant, current national,
regional and in-house regulations during
their usage of the crimping tool. The custo-
mer/operating company is also responsible
for installing any required extensions (e.g.
protective equipment as required by local
safety authorities) before further usage.
4.4 General safety instructions
The following safety instructions must be
observed when commissioning, using,
maintaining or dismantling the battery crim-
ping tool.
Understanding and safekeeping
• Before initially commissioning the crim-
ping tool, users and operators must have
completely read and understood this in-
struction manual, including the safety in-
structions.
• This instruction manual contains impor-
tant information to ensure a safe and
trouble-free operation of the crimping tool.
Always keep the document available in
the immediate vicinity of the crimping tool.
Responsibilities
Persons involved in the installation, opera-
tion and maintenance of the crimping tool
must have the following quali󰘰cations:
•Installation, commissioning and trai-
ning of operating personnel: This
must be a trained professional who un-
derstands the language of the operators
and the language of the operating instruc-
tions. This person must also have the
necessary competence to convey these
instructions along with the safety-relevant
information.
• Operations: This must be a trained pro-
fessional or a person instructed by a
trained professional.
• Maintenance, service and disassembly:
This must be carried out by a trained pro-
fessional.
Danger zones
• Danger zones: areas near the replacea-
ble crimping dies
Persons at risk: operators
Type of danger: crushing injuries
Responsibilities
The operator of the battery crimping tool is
responsible for ensuring that every person
involved in the installation or maintenance
of the tool has been thoroughly instructed
in its use by means of this instruction ma-
nual. The company operating this tool is

HARTING Electric GmbH & Co. KG
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HARTING Battery crimping tool 09 99 000 0990
also responsible for training the operating
personnel, which must include the follow-
ing points:
-Proper usage
-Safety regulations
-Operation of the tool and functions of the
various controls
-Danger zones
-Persons at risk
-Types of dangers
Initial commissioning
• The battery crimping tool may only be
set up when it is clean and functioning
smoothly (in proper technical condition).
Personnel tasked with the set up must be
aware of hazards and work safely.
• Put the battery crimping tool out of ope-
ration if you notice or assume that it
can no longer be operated safely. Make
sure that the tool cannot be accidentally
switched on.
Safety during operations
• Only one person at a time is permitted to
work on or with the battery crimping tool.
• Children and adolescents under 16 must
not be admitted to the work area when the
battery crimping tool is in use.
• The battery crimping tool may only be
operated in a dry and largely dust-free
environment, on condition that it is fully
functional.
• When working with the battery crimping
tool, wear protective goggles and do not
wear loose clothing, loose jewellery or
open hair that could get caught in the
crimping die.
•Note: During the entire crimping process,
the sequence can be interrupted – by mo-
ving the lever in the opposite direction.
• Stop working with the crimping tool
whenever you determine there is a mal-
function or problem with it. Any problems
or malfunctions must be 󰘰xed by a trained
technician before you resume operating
the crimping tool.
• Only operate the release lever to 󰘰x the
contact or to trigger the crimping process.
Avoid any unintentional operation of the
lever.
• Only use spare parts and recommended
accessories supplied by HARTING. If you
use other components, HARTING’s de-
claration of conformity for the product will
become void.
• Never carry the battery crimping tool with
your hand on the release lever. Always
keep the release lever and the transition
to the battery module dry and clean or
free of oil and grease.
• Maintenance work may only be carried
out by persons authorised and trained for
this activity!

11
General information and safety
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
ATTENTION: Do not get in contact with
any live parts!
Before carrying out any maintenance, make
sure that the battery crimping tool is discon-
nected from power supply!
Care instructions: Oil the battery-operated
crimping tool after every use and clean it
with a cloth. Only then put it back into the
tool box.
4.5 Cleaning instructions
4.6 Disposal
At the end of its service life, the battery crim-
ping tool should be brought to a disposal
centre or to the place where it was purcha-
sed. This will ensure that all components
are disposed of properly. Follow all relevant
national and regional regulations.

HARTING Electric GmbH & Co. KG
12
①
②
③
④
⑤
HARTING Battery crimping tool 09 99 000 0990
5. Technical details
Table 3: Speci󰘰cations of battery crimping tool 09 99 000 0990
Characteristic Value Specification Value
Weight
(incl. battery):
0.96 kg Battery capacity: 1.5 Ah, Li-Ion
Pressing force: 15 k N (maximum) Charging time: 40 minutes
Ambient
temperatures:
-10°C ... +40°C Battery voltage: 10.8 V
Processing time per crimping: < 1.5 s (depending on contact diameter)
Number of crimpings per battery: ~300 pressings (using 4 mm² contacts / per
battery charge)
Sound pressure level: < 70 dB (A) at a distance of 1 m
Vibrations: < 2.5 m/s² (weighted RMS of acceleration)
6. Components
HARTING Battery crimping tool
09 99 000 0990
Tool case
① Battery crimping tool
② Crimping dies
③ Locator for Han D®, E® and Han® C
contacts
④ Lithium ion battery
⑤ Battery charger

13
Suitable contacts and accessories
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
Table 4: Contacts to be processed
Contacts to be processed (series) Diameter
- Han D®:
- Han E®:
- Han®C:
0.14 – 1.5 mm²
0.5 – 4 mm²
1.5 – 4 mm² / 4 – 10 mm²
Accessories Part number
- Locator Han D®(0.14 – 1.5 mm²) 09 99 000 0991
- Locator Han E®(0.5 – 4 mm²) 09 99 000 0992
- Locator Han®C (1.5 – 4 mm²) 09 99 000 0993
- Replacement battery 09 99 000 0994
- Set: Crimping dies for Han® C (4 – 10 mm²)
+ Locator Han® C (4 – 10 mm²)
(not included in delivery)
09 99 000 0995
7. Suitable contacts and accessories

HARTING Electric GmbH & Co. KG
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①
②
③
HARTING Battery crimping tool 09 99 000 0990
8.1 Setting up the battery crimping tool
8. Set up and commissioning
This chapter describes the initial commissio-
ning process for the crimping tool, the crim-
ping itself as well as setup changes e.g. of
locator and battery. Before using the tool for
the 󰘰rst time, you must have read and under-
stood these instructions as well as the Gene-
ral Safety Instructions (➱ Chapter 4.4.)
Before setting up the crimping tool, the fol-
lowing warning message must be observed:
WARNING!
Risk of crushing fingers when inserting or removing
battery.
You risk crushing your fingers if your hands get into the area
between the receptacle and the contours of the battery while
detaching or attaching it. Therefore, hold the battery from the
sides so that fingers cannot be crushed.
8.1.1 Installation / exchange of battery
1. Check the charge level of the tool. If it
is too low (per activated green light, the
charge is +25% of the full charge), re-
charge the battery or use a replacement
battery.
2. Press the battery module lock button on
the base of the crimping tool ②.
3. Now, move the battery module in the di-
rection of the arrow ③ until it is released
from the base of the crimping tool.

15
④
⑤
⑥
Click!
a
Set up and commissioning
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
4. The battery of the crimping tool is unin-
stalled.
5. To reinsert a charged battery, push it
back into the base of the tool.
6. The “click”of the latch indicates the final
positioning (⑥).

HARTING Electric GmbH & Co. KG
16
①
Ⓐ
Ⓒ
Ⓓ
ⒸⒸ
ⒹⒹ
Ⓑ
②
Standard
Han®C
4 – 10 mm²
HARTING Battery crimping tool 09 99 000 0990
NOTICE
Released (III)
Fixed (II)
Opened (I)
Positions of release lever
The lever for triggering the crimping process can take
three di󰘯erent positions:
Stage III (upper position): crimping die closed, crimping
process starts
Stage II (mid position): crimping die mechanically clo-
sed, contacts can be inserted
Stage I (lower position): crimping die opened
8.1.2 Insertion of the crimping die
As a standard, the battery crimping tool
09 99 000 0990 is equipped with a die for
processing crimped contacts of the Han D®,
E®and Han®C series. The contacts may
have a maximum diameter of 4 mm. To pro-
cess larger contacts, a Han®C crimping die
for conductors with cross-sections of 4, 6 or
10 mm² is available.
The installation of the crimp die is descri-
bed using the example of the standard
crimp die for this tool. From the rear, de-
pending on the type of contact, a special
positioner must be inserted to ensure a
uniform processing quality for the various
crimp contacts (➱Chapter 8.2 Crimping).
Assembly steps
WARNING!
Risk of cru-
shings: The
ready-to-use battery crimping tool
can be released accidentally.
▸Always disconnect the battery before
you insert or remove the crimp die!
1. Loosen the 󰘰xing screws Ⓐ+Ⓑ from the
tool head.
2. Insert the die (Ⓒ+Ⓓ) that is suitable for
your type of contact in the speci󰘰ed posi-
tions of the tool (⇨ red arrows). Check if
the crimping die is correctly seated while
the release lever is in position II.
Note: The crimping die is correctly aligned
if the inscriptions are legible and not
upside down (⇨ Ⓒ+Ⓓ).

17
③
⑤
⑥
⑦
④
Ⓐ
Ⓑ
Set up and commissioning
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
3. Pull up the release lever until the crimp
die closes 󰘰rmly and both parts of the
crimping die hold position.
4. Keep the tool closed so that the up-
per and lower crimp die remain 󰘰xed in
the correct position until you tighten the
screws.
5. Use a 3.5 mm Allen key to tighten both
󰘰xing screws (⇨ red arrows). The recom-
mended torque is 2 Nm.
Note: Make sure to use the correct faste-
ning screws to position the locator.
Insert the longer screw Ⓑ in the lo-
wer die, and the shorter one Ⓐ in the
upper die.
6. Open the crimping tool again.
7. Insert the locator in the designated
position and 󰘰x it with the supplied screw
(➱ red arrow).
▸Reinsert the battery.

HARTING Electric GmbH & Co. KG
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②
①
③ ④
HARTING Battery crimping tool 09 99 000 0990
8.2 Crimping
WARNING!
Risk of injury from bumping and crushing!
The battery crimping tool may only be set up and operated
in a technically perfect, complete and functional condition.
Work carefully and be aware of safety and hazards. Wear
protective goggles when working with the crimping tool. Do
not wear loose clothing and/or long, open hair. These could
get caught in the crimping tool.
Interrupt the work process if you notice any faults in the crim-
ping tool. Correct the fault before you continue processing.
Only trained personnel may use the crimping tool or work
on it. Two or more operators must not work on or with the
same crimping tool at the same time.
Before starting to crimp: Check whether
you have selected the correct locator for
processing the selected contact type. The
locator automatically selects the required
recesses for crimping your contact type.
Locator and contact dimensions
Posi-
tion
Contact
type
Diameter
① Han D®0.14 ... 1.5 mm²
② Han E®0.5 ... 4 mm²
③ Han®C 1.5 ... 4 mm²
④Han®C 4 ... 10 mm²
1. Remove the battery and attach the
positioner suitable for your contact type.

19
①
②
③
④
Set up and commissioning
Instruction manual tool 09 99 000 0990 / Betriebsanleitung Werkzeug 09 99 000 0990
NOTICE
Released (III)
Fixed (II)
Opened (I)
Positions of release lever
The lever for triggering the crimping process can take three
different positions:
Stage III (upper position): crimping die closed, crimping
process starts
Stage II (mid position): crimping die mechanically clo-
sed, contacts can be inserted
Stage I (lower position): crimping die opened
1. Insert the contact into the appropriate
positioner/ the appropriate position in the
crimp die.
2. Fix the contact between the upper and
lower die.
3. Lower the release lever so that the die
opens and the contact can be readjusted
if necessary.
4. Fix the positioned contact and insert the
stripped wire.
Lever:
Stage I
Lever:
Stage II
Lever:
Stage I
Lever:
Stage II

HARTING Electric GmbH & Co. KG
20
⑥
⑤
⑦
HARTING Battery crimping tool 09 99 000 0990
5. Crimping
6. Open the crimping die again!
7. Remove the cable end with the crimped
contact and carry out a visual inspection.
Observe the following note!
NOTICE
Remove contact
only when the
crimping die is
completely open!
Make sure that contact and positioner fit
together when crimping.
Do not remove the fully crimped contact
too soon, otherwise you will damage the
contact.
Wait until the crimp die is completely open
before removing it.
Lever:
Level III
Lever:
Level I
Lever:
Level I