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AMP* PRO-CRIMPER* Il Instruction Sheet Hand Tool Assembly 90759-1 408-9962 AMP with Die Assembly 90759-2 10JAN95 RevA En na PROPER USE GUIDELINES _ Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. AMP hand tools are intended for occasional use and low volume applications. AMP offers a wide selection of powered application equipment for extended-use, production operations. LOCATOR STATIONARY JAW , ASSEMBLY LEE (Supplied wih V7 BACK OF TOOL Die Assembly) j SHA 2 (Wire Side) MW KE» Og i? /~% i CI" FRONTOFTOOL we PIVOT PI (Locator Side) ( A EP? \\ IVOT PIN ASSEMBLY / ( aa) PRO-CRIMPER I! HAND TOOL War 7} FRAME 354940-1 Move JAW AN Y (See AMP Instruction \\ €) Sheet 408-9930) RATCHET WN ADJUSTMENT WHEEL The PRO-CRIMPER II Hand Tool is a “Commercial” grade too! and is STATIONARY designed primarily for field installation, repair, maintenance work, or HANDLE 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 application specification, but may not comply with other feature parameters of the specification. AMP offers a variety of tools to satisfy MOVING HANDLE your performance requirements. For additional information, contact the Technical Assistance Center at 1-800-722-1111. oo DIE ASSEMBLY LOCATORASSY CONTACT —=—__ art PART NUMBER PART NUMBER FAMILY’ ANG ne fm ing) 1,50 to 2.39 3.2010 3.71 Mini Universal 22-20 [.059to.094) — [.126to.146) 90759-2 58516-1 MATE-N-LOK* OR os OR (2) 3.38 max .50 to 3.99 me t+ Supplied with die assembly, also available separately. + Contact the AMP Technical Assistance Center (see below) . for specific contact part numbers. Figure 1 1. INTRODUCTION Dimensions on this sheet are in millimeters [with inch equivalents provided in brackets]. Figures . AMP PRO-CRIMPER I! Hand Too! F i ‘dontificati Assembly 90759-1 consists of Die Assembly and Rusia are identlcation only nt 90759-2 and AMP PRO-CRIMPER II Hand Tool . ’ Frame 354940-1. The die assembly consists of crimping dies and a locator assembly. Read these Reasons for reissue are provided in Section 11, instructions thoroughly before crimping any contacts. | REVISION SUMMARY. A ‘AMP Incorporated, Harrisburg, PA17105 TECHNICAL ASSISTANCE CENTER 1-800-722-1111 AMP FAX/PRODUCT INFO 1-800-522-6752 tof5 ‘This AMP controlled document is subject to change. For latest revision call the AMP FAX number. ‘©Copyright 1995 by AMP Incorporated. Al! Rights Reserved. “Trademark Loc 8

AMP AMP PRO-CRIMPER Il Hand Tool Assembly and Die Assembly 408-9962 el NUT 3 LOCATOR GB LL ~~ ASSEMBLY TOOL FRAME RS — Cr, ~ Z _—__ LOCATOR ¥ a, © : fo Bxe5 a DIE RETAINING INSULATION SN . PINS CHAMFER: CRIMPER Ye , ™ Jo 0 Va . a Vain VLG ~

0 P 4 Ate we >

WIRE CRIMPER Wy 9) 1 LP QYy \\ > Vo oy) LY of ae ees OFFSET « NE oN WIRE ANVIL NSULATION ™ CHAMFER ANVIL DIE RETAINING SCREWS a Figure 2 2. DESCRIPTION (Figures 1 and 2) screw just enough to hold the dies in place. Do not : . . tighten the screw completely at this time: The tool features a tool frame with a stationary jaw . | | and handle, a moving jaw, a moving handle, and an 5. Place the wire crimper and insulation crimper so adjustable ratchet that ensures full contact crimping. that their chamfered sides and their marked The tool frame holds a die assembly with two surfaces face outward, when mounted in the ~ crimping sections. stationary jaw of the tool frame. The die assembly features a wire anvil, an insulation 6. Insert the two die retaining pins. anvil, a wire crimper, and an insulation crimper. 7. Insert the long die retaining screw through the Attached to the outside of the frame is a locator jaw and through both crimper dies, and tighten the assembly, which contains a locator, a spring retainer, screw just enough to hold the dies in place. Do not and a contact support. tighten the screw completely at this time. Die retaining pins and die retaining screws are used 6 Carefully close the too) naricles, making sure to position and secure the dies in the tool frame. A pers ain properly. nut ig used on the upper die retaining screw to hold Continue closing the too! handles until the ratchet the locator sesemblyin lace. 9 in the tool frame has engaged sufficiently to hold vine . the anvils and crimpers in place, then tighten both die retaining screws. 3. INSTALLATION AND REMOVAL OF DIE SET AND LOCATOR ASSEMBLY (Figure 2) 9. Place the locator assembly over the end of the . long screw, and position the locator assembly 1. Open the tool handles and remove the two die against the side of the tool jaw. retaining screws from the tool jaws. 10. Place the nut onto the end of the long screw 2. Place the wire anvil and insulation anvil so that and tighten the nut enough to hold the locator their chamfered sides and their marked surfaces assembly in place, while still allowing the locator to face outward, when mounted in the moving jaw of slide up and down. the tool frame. . . 11. To disassemble, close the too! handles until the : 3. Insert the two die retaining pins. ratchet releases, remove the nut, the locator assembly, the two die retaining screws, and the 4. Insert the short die retaining screw through the four die retaining pins, and slide the anvils and ~ jaw and through both anvil dies, and tighten the crimpers out of the tool jaws Eee 20f5 Rev A

ANP AMP PRO-CRIMPER Il Hand Tool Assembly and Die Assembly 408-9962 eel 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) This tool is provided with a crimp adjustment The contact is preset prior to shioment feature. ital, the crimp height should be contact support iaieres ‘rior to shipment, verified as specified in Figure 4. Refer to but minor adjustment may be necessary. Section 6, CRIMP HEIGHT INSPECTION, and

7 A ine i Section 7, CRIMP HEIGHT ADJUSTMENT, to

4, Make a sample crimp and determine if the pagination i an contact is straight, bending upward, or bending verity crimp height before using the tool to crimp . downward. desired contacts and wire sizes. - A . Refer to the table in Figure 1 and select wire of the fe it adlustment is required, owen the screw that specified size and insulation diameter. Strip the wire . ‘olds ny contact support onto the locator to the length indicated in Figure 1, taking care not to assembly. nick or cut wire strands. Select an applicable contact NOTE The ratchet has detents that create audible and identify the appropriate crimp section according clicks as the too! handles are closed. to the wire size markings on the tool. Refer to Figure 3 and proceed as follows: 3. Place a contact with wire into the proper nest 1. Hold the tool so that the back (wire side) is and close the tool handles until the ratchet reaches Sci the sixth click, or until the contact support touches facing you. owe ‘an handles together and the contact. . . 2. Holding the contact by the mating end, insert the 4, Slightly loosen the nut that holds the locator contact — insulation barrel first — through the front assembly onto the tool frame. of the too! and into the appropriate crimp section. 5. Move the contact support as required to 3. Position the contact so that the mating end of eliminate the bending of the contact. the contact is on the locator side of the tool, and so . that the open “U” of the wire and insulation barrels 6. Tighten the nut and close the handles until the face the top of the tool. Place the contact up into ratchet releases. the nest so that the movable locator drops into the ‘ slot in the contact. Refer to Figure 3. Butt the front 7, Remove and inspect the contact. end of the wire barrel against the movable locator. 8. Make another sample crimp. If the contact is Make ie i ic : . ION @ sure that both sides of the insulation barrel straight, tighten the contact support screw. If the CAUTI i mpi " ~ contact is still being bent during crimping, repeat for seat Ainge tibad hearer the adjustment procedure. contact. 4. Hold the contact in position and squeeze the 5. CRIMPING PROCEDURE tool handles together until ratchet engages a CONTACT support LOCATOR screwror S57 2 ( ) CONTACT A, 6 | SUPPORT Uj ¥ 0 conmct _ |, STRIP N aie oe) 5 F LENGTH ) — PRY, | Oy N ~ = V4 <M Yy aD WIRE NY NN J 6 LOCATOR N WZ , rel Gy $ / IN WIRE \\. WIRE

7 STOP SLOT INSERTED

YY, SQ TO STOP Figure 3 Se ooo RevA 3of5

ANP AMP PRO-CRIMPER Il Hand Tool Assembly and Die Assembly 408-9962 Snel sufficiently to hold the contact in position. Do NOT POSITION deform insulation barrel or wire barrel. POINT ON CENTER OF | . . y 5. Insert stripped wire into contact insulation and poe ~\\ \\ ~ wire barrels until it is butted against the wire stop, SEAM as shown in Figure 3. Tt 6. Holding the wire in place, squeeze tool handles MODIFIED together until ratchet releases. Allow tool handles ANVIL “AY + .05[.002] to open and remove crimped contact. ' The crimped contact may stick in the crimpin WIRE SIZE CRIMP SECTION CRIMP HEIGHT MNGHN area but ho contact canbe easiy emovedty -«AWG(MAX)-(WIRESZEMARKING) DIM. () Figure 3). 81 20 22-20 [.032} 7. Check the contact’s crimp height as described in 4.02 Section 6, CRIMP HEIGHT INSPECTION. If 18 18, (2) 22 [.040) necessary, adjust the crimp height as described in Section 7, CRIMP HEIGHT ADJUSTMENT. ——~ex——— Figure 4 7, CRIMP HEIGHT ADJUSTMENT (Figure 5) 6. CRIMP HEIGHT INSPECTION 1. Remove the lockscrew from the ratchet adjustment wheel. This i . . a Ta TT ee ee Oa ne rede with 2. Witha screwdriver, adjust the ratchet wheel micrometer (Crimp Height Comparator from the locator side of the tool. RS-1019-5LP) which may be purchased from: _ Or oa—oorvvvm" _ SCREWDRIVER , Shearer Industrial Supply Co. VALCO /

20 North Penn Street or 1410 Stonewood Drive “

York, PA 17401-1014 Bethlehem, PA 18017-3527 ip ~ Oy Proceed as follows: . \\, f ? \\Y 1. Refer to Figure 4 and select a wire (maximum \\ size) for each crimp section listed. Xe 6 \\\\ RATCHET NN Se | 1G \\ 2. Refer to Section 5, CRIMPING PROCEDURE, BRAGS TMENT \\ & and crimp the contact(s) accordingly. 3. Using a crimp height comparator, measure the <( C wire barrel crimp height as shown in Figure 4. If the crimp height conforms to that shown in the table, LOCKSCREW the tool is considered dimensionally correct. If not, (Typ) the tool must be adjusted. Refer to Section 7, Se CRIMP HEIGHT ADJUSTMENT. Figure 5 ; Nace eee 405 RevA .

ANP AMP PRO-CRIMPER Il Hand Too! Assembly and Die Assembly 408-9962 an eee 3. Observe the ratchet adjustment wheel. If a 10. REPLACEMENT tighter Sem is te SONG es djustment Customer-replaceable parts are shown in Figure 1 higher-numbered setting. If a looser crimp is Available separately, AMP PRO-CRIMPER I Repair — required, rotate the adjustment wheel Kit 679221 ~1 includes a replacement nut and a CLOCKWISE to a lower-numbered setting. variety of pins, rings, screws, and springs. If the dies are damaged or worn excessively, they must be . 4. Replace the lockscrew. replaced. Order the repair kit and replaceable parts l - height Tne est is acpeptabie, replace and purchase order to 1-717-986-7605, or write to: unacceptable, continue to adjust the ratchet, and CUSTOMER SERVICE (38-35) again measure a sample crimp. AMP INCORPORATED P.O. BOX 3608 8, MAINTENANCE HARRISBURG, PA 17105-3608 Ensure that the toot and dies are clean by wiping them with aclean, soft cloth. Remove any debris with 11, REVISION SUMMARY a clean, soft brush, Do not use objects that could Since the previous release of this sheet, the following ge - i », Keep chan ere made: closed to prevent objects from becoming lodged in ges Ww the crimping dies, and store in a clean, dry area. Per EC 0150-3338-95 @ Added note in Figure 1. © Deleted note in Section 1, INTRODUCTION 9. VISUAL INSPECTION e Changed Crimp Height Comparator The crimping dies should be inspected on a regular RH-1019-LAP to RS-1019-5LP. basis to ensure that they have not become worn or @ Changed York Machinery & Supply Co. to damaged. Inspect the crimp sections for flattened, Shearer Industrial Supply Co. chipped, worn, or broken areas. If damage or abnormal wear is evident, the tool must be replaced. Per EC 0990-0252-93 _ See Section 10, REPLACEMENT. @ Added “REVISION SUMMARY.” . ES RevA 5of5