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Tooling Instructions

Hand Crimping Instructions

Inspection Information for Removable Crimp Contacts

Size 8 Power Contacts with Annular Ring

Applicable Tools

9504-1-0-0: A hand-actuated tool that utilizes a two-piece crimp die.
9504-19-1-0: A positioner die used to apply the crimp forces to the contact.
9504-20-1-0: A positioner die used to apply the crimp forces to the contact.

Instructions

Prepare wire by stripping off the insulation per Positronic recommended strip length found in the Strip Length Cross Reference. Position the contact and wire in the die so the end of the contact crimp barrel is flush with the side of the die. Squeeze handles together until ratchet releases. Handle will return to open position. Remove crimped contact and wire. Inspect crimp as specified in Inspection Information for Removable Crimp Contacts.

Size 16 High Conductivity Power Contacts

Applicable Tools

9509-4-0-0: A hand-actuated indenter-style crimp tool with preset crimp depth.
9509-5-0-0: A positioner used to accurately position the contact in the crimp tool. This positioner is not adjustable.

Instructions

Prepare wire by stripping off the insulation per Positronic recommended strip length found in the Strip Length Cross Reference. Insert the contact and stripped wire into indentor opening from side opposite the positioner. Squeeze handles together until ratchet releases. Handle will return to open position. Rotate the crimped contact 45 degrees and crimp again. Remove crimped contact and wire. Inspect crimp as specified in Inspection Information for Removable Crimp Contacts.

Size 16 Power Contacts

Applicable Tools

9501-0-0-0: A hand-actuated indenter-style hand tool with an adjustable crimp depth feature.
9502-1-0-0: A turret positioner adjustable for different contacts. The purpose is to accurately position the contact in the crimp tool.

Instructions

Positioner Installation
Tool must be in open position. To open, squeeze tool handle all of the way closed until the ratcheting mechanism reaches the stop. Then release the grip and the tool will open. Press turret trigger latch which releases turret to indexing position. Seat turret assembly against the retaining ring with socket holes lined up with tapped holes. Tighten socket head screws with 9/64 inch hex key. Rotate the knurled silver positioner knob to the 1/2 blue, 1/2 red position until it is lined up with the index mark. Push downward until it clicks and is flush with the top of the turret assembly.

Crimping Contact
Rotate the selector knob on the hand tool to the wire gague to be crimped. Prepare wire by stripping off the insulation per Positronic recommended strip length found in the Strip Length Cross Reference. Insert the contact and stripped wire into indentor opening from side opposite the positioner. Squeeze handles together until ratchet releases. Handle will return to open position. Remove crimped contact and wire. Inspect crimp as specified in Inspection Information for Removable Crimp Contacts.

Size 16 Shielded Contacts

Applicable Tools

9506-0-0-0: A crimp tool comprised of a hand tool and die. This tool has no adjustable settings.

Instructions

Slide contact ferrule over coax cable away from stripped area. Strip coax cable per Positronic specified dimensions found in the Strip Length Cross Reference. Open the braid/shield into a cone shape using a small pointed tool. Insert stripped coax cable into contact taking care that all of the center conductor strands are captured in the contact and that the braid/shield is equally distributed around the outside of the contact. Carefully slide ferrule onto the back of the contact, covering the braid/shield. Align the two milled window areas of the contact with the slot in the thin metal part of the die and gently push the contact back until the windows are aligned with the two (2) square dowel pins in the die. The ferrule side of the contact should now occupy the hex area of the die. Squeeze handles together until ratchet releases. Pull crimped contact out of tool. Inspect crimp as specified in Inspection Information for Removable Crimp Contacts.

Size 20 and 22 Signal Contacts

Applicable Tools

9507-0-0-0: A hand-actuated indenter-style hand tool with an adjustable crimp depth feature.
9502-*: These positioners are non-adjustable. Their purpose is to accurately position the contact in the crimp tool.

Instructions

Positioner Installation
Tool must be in open position. To open, squeeze tool handle closed until the ratcheting mechanism reaches the stop. Release the grip and the tool will open. Remove safety clip from positioner guide. Select the correct positioner for contact to be crimped from the Removable Contact Tooling Cross Reference. Insert the positioner into positioner guide on the hand tool and turn 90 degrees clockwise until the bayonet pins lock. The positioner is spring loaded, so gentle pressure should be applied against the tool to allow the bayonet pins to engage and lock. Install safety clip back into the positioner guide. Identify wire size and corresponding selector number as shown on data plate decal on the positioner. With tool still in open position, raise and rotate selector knob until the correct number setting is in line with the Sel. No. arrow. Release selector knob so that it locks into place.

Crimping Contact
Prepare wire by stripping off the insulation per Positronic recommended strip length found in the Strip Length Cross Reference. Insert contact and prepped wire into indentor opening from side opposite the positioner. Squeeze handles together until ratchet releases. Handle will return to open position. Remove crimped contact and wire. Inspect crimp as specified in Inspection Information for Removable Crimp Contacts.

Removing Positioner
Remove safety clip and reverse procedure as described above.

Size 8 Shielded Contacts

Applicable Tools

9504-1-0-0: A hand-actuated crimp tool. This tool utilizes a two-piece crimp die.
9504-15-1-0, 9504-14-1-0 or 9504-15-1-0: These two-piece crimp dies are used to crimp the inner conductor, then the outer shield of then coax cable when terminating size 8 shielded contacts.

Instructions

Slide contact ferrule over coax cable away from stripped area. Strip coax cable per Positronic specified dimensions found in the Strip Length Cross Reference. Open the braid/shield into a cone shape using a small pointed tool. Insert stripped coax cable into contact taking care that all of the center conductor strands are captured in the contact and that the braid/shield is equally distributed around the outside of the contact. Carefully slide ferrule onto the back of the contact, covering the braid/shield. Place the contact in the lower die half so that the shaped dowel pin is aligned with the center conductor crimp barrel. Squeeze handles together until ratchet releases. Move contact to the hex crimp area so that the whole length of the ferrule will be crimped. Squeeze handles together until ratchet releases. Pull crimped contact out of tool. Inspect crimp as specified in Inspection Information for Removable Crimp Contacts.