TE Connectivity PRO-CRIMPER III User manual

Stationary Jaw Back of Tool
(Wire Side)
Pivot Pin
PRO-CRIMPER III
Hand Crimping Tool
Frame 354940-1 
(408-9930)
Stationary
Handle
Moving Handle
Ratchet
Adjustment Wheel
Moving Jaw
Die Assembly
Front of Tool
(Locator Side)
Locator Assembly
(Supplied with Die Assembly)
TE DIE
ASSEMBLY TE LOCATOR ASSEMBLY† CONTACT FAMILY‡ WIRE
SIZE (AWG) INSUL DIA STRIP LENGTH
90871-2 58516-1 .093 Commercial
Pin and Socket 20-18 3.56 [.140] Max 3.96 to 4.72 [.156 to .186]
16-14
† Supplied with die assembly. Also available separately.
‡ Contact the Tooling Assistance Center or Product Information (seebelow) for specific contact part numbers.
©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
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Instruction Sheet
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.te.com LOC B
408-9966
PRO-CRIMPER* III Hand
Crimping Tool Assembly 90871-1
with Die Assembly 90871-1 and -2 13 OCT 11 Rev C
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.
Figure 1
1. INTRODUCTION
PRO-CRIMPER III Hand Crimping Tool Assembly
90871-1 consists of Die Assembly 90871-2 and PRO-
CRIMPER III Hand Crimping Tool Frame 354940-1.
The die assembly consists of crimping dies and a
locator assembly.
Read these instructions thoroughly before crimping
any contacts.
NOTE
i
Dimensions on this sheet are in millimeters [with
inchequivalentsprovidedin brackets].Figuresand
illustrations are for identification only and are not
drawn to scale.
Reasons for reissue are provided in Section 11,
REVISION SUMMARY.
2. DESCRIPTION (Figure 1 and Figure 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 two 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.

Nut
Locator
Chamfer
Insulation
Anvil
Wire
Crimper
Insulation
Crimper
Locator
Assembly Tool Frame
Die Retaining
Pins
Die Retaining
Screw
Die Retaining
Screw
Offset
Wire Anvil
Chamfer
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Figure 2
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.
4. CONTACT SUPPORT ADJUSTMENT (Figure 3)
NOTE
i
The contact support is preset priorto 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.

NOTE
i
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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
sixt# click, or until the contact support touches the
contact.
4. Slightly loosen the nutthat 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
NOTE
i
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
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 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.
CAUTION
!
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.
Contact
Support
Adjustment
ScrewforContact
Support
Locator
Back of Tool
(Wire Side)
Wire
Contact
(Typ)
Locator
in Wire
Stop Slot
Strip
Length
Wire
Inserted
to Stop
Figure 3

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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.
NOTE
i
Thecrimpedcontactmaystickinthecrimpingarea,
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 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. TE 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.
PositionPoint
on Center of
Wire Barrel
Opposite
Seam
Modified Anvil
WIRE SIZE
AWG (Max) CRIMP SECTION (Wire Size Marking) CRIMP HEIGHT DIMENSION “A”
18 20-18 1.07 [.042]
14 16-14 1.45 [.057]
Figure 4
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.
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)
Figure 5
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.

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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
TE 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 (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
11. REVISION SUMMARY
Revisions to this instruction sheet include:
•Changed company name and logo

Tooling Used With 90871-2
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