Tyco Electronics 90654-1 User manual

Instruction Sheet
PRO- CRIMPER* III Hand
Crimping Tool Assembly 90654- 1 408--9855
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
21 AUG 09 Rev Dwith Die Assembly 90654- 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
Tooling 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.])
M
l
t
i
l
k
18 1.96 to 2.54
[.077 to .100]
90654--2 58515--1
Multilock
.070 Series
Contacts
16 2.21 to 2.59
[.087 to .102]
4.50 to 5.00
[.177 to .197]
C
o
n
t
a
c
t
s
20 1.75 to 2.49
[.069 to .098]
{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 90654--1 consists of Die Assembly
90654--2 and PRO--CRIMPER III Hand Crimping Tool
Frame 354940--1. See Figure 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
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408- 9855
PRO- CRIMPER III Hand Crimping Tool Assembly 90654- 1
Rev D2 of 6 Tyco Electronics Corporation
Figure 2
Nut
Chamfer
Wire Crimper
Offset
Wire Anvil Insulation
Anvil
Chamfer
Insulation Crimper
Locator
Assembly Tool Frame
Die Retaining
Pins
Die Retaining
Screws
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 three
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- 9855
PRO- CRIMPER III Hand Crimping Tool Assembly 90654- 1
3of 6Rev DTyco 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
must 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
Adjustment
Screw for
Contact
Support
Contact
Support Locator
Back of Tool
(Wire Side)
Wire
Contact
(Typ) Strip
Length
Wire Inserted
to Stop
Locator
in Wire
Stop Slot
NOTE
i
NOTE
i
NOTE
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408- 9855
PRO- CRIMPER III Hand Crimping Tool Assembly 90654- 1
Rev D4 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 (Figure 5)
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
Modified
Anvil “A
”
Wire Size
AWG (Max)
Crimp Section
(Wire Size Marking)
Crimp Height
Dim. (A) and
Tolerance (+)
18 18 1.054 .051
[.0415 .0020]
16 16 1.181 .051
[.0465 .0020]
20 20 .978 .051
[.0385 .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
Screw
Locking Screw
(Typ)
CAUTION
!
NOTE
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408- 9855
PRO- CRIMPER III Hand Crimping Tool Assembly 90654- 1
5of 6Rev DTyco 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:
SInformation in Section 6 was revised;
STE logo was applied;
SFormat was updated to current corporate
requirements; and
SThe back page (tools using Die Assembly
90654--2) was added.

408- 9855
PRO- CRIMPER III Hand Crimping Tool Assembly 90654- 1
Rev D6 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 90654- 2 Can Be Used In the Following Tools: