TE Connectivity PRO-CRIMPER III User manual

Instruction Sheet
©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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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
PRO-CRIMPER* III Hand Crimping
Tool Assembly 90800-1 with
Die Assembly 90800-2 408-4007
19 APR 11 Rev D
Figure 1
1. INTRODUCTION
PRO-CRIMPER III Hand Tool Assembly 90800-1
consists of PRO-CRIMPER III Hand Tool Frame
354940-1 and Die Assembly 90800-2. The tool
assembly is used to crimp the contacts given in
Figure 1,
Read these instructions thoroughly before using the
tool assembly.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
For additional information on the hand tool frame, refer
to 408-9930.
Reasons for reissue of this instruction sheet are
provided in Section 9, REVISION SUMMARY.
2. DESCRIPTION (See Figure 1)
The tool consist of a stationary jaw and handle, a
moving jaw and handle, and an adjustable ratchet that
ensures full crimping. The tool features a ratchet
adjustment wheel for adjusting the crimp height.
A locator assembly is attached to the tool frame and
consists of a locator, spring retainer, and contact
support. The contact support prevents the contact from
bending during crimping. A nut used on the long die
retaining screw holds the locator assembly in place.
The die assembly consists of two anvil dies (wire and
insulation) and two crimper dies (wire and insulation).
DIE ASSEMBLY LOCATOR
ASSEMBLY PRODUCT FAMILY
WIRE
SIZE RANGE
(AWG)
INSULATION
DIAMETER
(mm [in.])
STRIP LENGTH
(mm [in.])
90800-2 58516-1 AMPLIMITE* HD
Crimp-Snap Contacts 28-22 0.76-1.02 [.030-.040]
3.56-3.96
[.140-.156]
NOTE
i
Die Assembly
Moving Jaw
Ratchet Adjustment
Wheel
Stationary Jaw
Back of Tool Frame
(Wire Side)
Pivot Pin
Ratchet
PRO-CRIMPER III Hand Tool
Frame 354940-1 (408-9930)
Stationary Handle
Moving Handle
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 Application
Specification (114-series), but may not comply with other feature parameters of the
specification. TE Connectivity offers a variety of tools to satisfy your performance
requirements. For additional information, contact the Tooling Assistance Center at
1-800-722-1111.
Die Retaining Screw
(2 Places)
Locator Assembly
(Supplied with Die Assembly)
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.
ORIGINAL INSTRUCTIONS

408-4007
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Rev D
Figure 2
When closed, the dies form two crimping chambers.
Each die is held in the tool frame by a retaining screw
and two retaining pins.
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY
AND LOCATOR ASSEMBLY
1. Close the tool handles until the ratchet releases,
then allow the handles to open fully.
2. Remove the two die retaining screws from the
tool jaws.
3. Slide the wire anvil and insulation anvil dies onto
the moving jaw so that the chamfers and marked
surfaces face outward as shown in Figure 2, then
insert the two die retaining pins through the holes in
the moving jaw and into the holes in the dies.
4. Thread, but do not tighten, the short die retaining
screws through the holes of the moving jaw and into
the holes in both anvil dies.
5. S
lide the wire crimper and insulation crimper dies
onto the stationary jaw so that the chamfers and
marked surfaces face outward as shown in Figure 2,
then insert the two die retaining pins through the holes
in the stationary jaw and into the holes in the dies.
6. Thread, but do not tighten, the long die retaining
screws through the holes of the moving jaw and into
the holes in both crimper dies.
7. Carefully close the tool handles, making sure that
the dies align properly. Continue closing the
handles until the ratchet has engaged sufficiently to
hold the dies in place.
8. Tighten the die retaining screws using the
appropriate screwdriver.
9. Place the locator assembly over the end of the
long die retaining screw, and position the locator
assembly against the side of the tool jaw.
10. Place the nut onto the end of the long die
retaining 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, locator assembly,
the two die retaining screws, and four die retaining
pins, then, slide the dies out of the tool jaws.
4. CRIMPING PROCEDURE
The tool frame is provided with a crimp adjustment
feature. Initially, the crimp height should be verified
according to Section 6, CRIMP HEIGHT
INSPECTION, and if necessary, adjusted
according to Section 7, CRIMP HEIGHT
ADJUSTMENT before using the tool.
Refer to Figure 1, and select wire of the specified size
and insulation diameter. Strip the wire to the
dimension given in Figure 1, taking care not to nick or
cut wire strands. Then proceed as follows:
1. Hold the tool so that the back (wire side) faces
you. Close the tool handles until the ratchet
releases, then allow the handles to open FULLY.
2. Insert the contact (insulation barrel first) into the
front of the appropriate crimping chamber (refer to
the markings on the die).
3. Position the contact so that the mating end is on
the locator side of the tool frame and the open “U” of
the wire barrel and insulation barrel faces the top of
Insulation Anvil
Die
Long Die Retaining
Screw
Die Retaining Pin
(4 Places)
Insulation
Crimper
Die Chamfer
Wire Anvil
Die
Offset
Chamfer
Wire Crimper
Die
Locator Assembly
Nut
Locator
Tool Jaws
Short Die Retaining
Screw
NOTE
i

408-4007
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Rev D
Figure 3
the tool frame. Place the contact up into the
crimping chamber so that the locator drops into the
slot in the contact. Refer to Figure 3. Butt the front
end of the wire barrel against the locator.
Make sure that both sides of the insulation barrel
are started evenly into the crimping chamber.
DO NOT attempt to crimp an improperly positioned
contact.
4. Hold the contact in position, and close the tool
handles until the ratchet engages sufficiently to hold
the contact in position. DO NOT deform the
insulation barrel or wire barrel.
5. Insert the stripped wire into contact insulation
barrel and wire barrel until it is butted against the
wire stop as shown in Figure 3.
6. Holding the wire in place, close the tool handles
until the ratchet releases.
7. Allow the tool handles to open FULLY, and
remove the crimped contact.
The crimped contact may stick in the crimping area;
however the contact can be removed by pushing
downward on the top of the locator (see Figure 3).
8. Check the contact crimp height, and if necessary,
adjust the crimp height
DO NOT use defective or damaged products.
5. ADJUSTMENTS
5.1. Contact Support
The contact support is preset prior to shipment, but
minor adjustment may be necessary if the contact is
bending during crimping.
Proceed as follows:
1. Make a sample crimp and determine if the
contact is bending (upward or downward).
2. Loosen the screw that holds the contact support
onto the locator assembly.
3. Place a contact with a wire into the proper
crimping chamber, and close the tool handles until
the ratchet reaches the sixth click or until the
contact support touches the contact.
The ratchet has detents that create audible clicks
as the tool handles are closed.
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, then close the handles until the
ratchet releases.
7. Remove and inspect the contact. 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.
5.2. Ratchet Adjustment
The tool ratchet mechanism features an adjustment
wheel with numbered settings. The adjustment wheel
controls the amount of handle pressure exerted on the
jaws during crimping. If the crimp is not acceptable,
adjust the ratchet as follows:
1. Remove the lockscrew from the ratchet
adjustment wheel. Refer to Figure 4.
2. Using a screwdriver, adjust the ratchet wheel
from the front of the tool.
Contact Support
Adjustment
Screw for
Contact Support
Wire
Back of
Tool Frame
(Wire Side)
Locator in
Wire Stop Slot
of Contact
Wire Strip Length
Crimping
Chamber
Wire Inserted
to Wire Stop
!
CAUTION
NOTE
i
!
CAUTION
NOTE
i

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Rev D
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.
Figure 4
4. Re-install the lockscrew.
5. Make a sample crimp. If the crimp is acceptable,
the adjustment setting is correct. If the crimp is
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp.
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
market crimp height comparators. Refer to Instruction
Sheet 408-7224 for detailed information on obtaining
and using a crimp height comparator.
Proceed as follows:
1. Refer to Figure 5, and select a maximum size
wire for each crimping chamber.
2. Crimp the contacts according to Section 4.
3. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. If the
crimp height conforms to the dimension, the tool
assembly is considered dimensionally correct. If
not, the tool frame must be adjusted. Refer to
Paragraph 5.2, Crimp Height Adjustment.
7. MAINTENANCE AND INSPECTION
7.1. Maintenance
1. Ensure that the tool frame 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 any components.
2. When not in use, keep tool handles closed to
prevent objects from becoming lodged in the dies,
and store in a clean, dry area.
Figure 5
3. Remove all lubrication and accumulated film from
the dies by immersing the dies in a suitable
commercial degreaser.
7.2. Visual Inspection
1. Inspection of the tool and dies should be made on
a regular basis to ensure that they have not become
worn or damaged.
2. Make sure that the proper die retaining screws
are properly secured.
3. Inspect the crimping chambers of the die
assembly for flattened, chipped, worn, or broken
areas. If damage or abnormal wear is evident, the
dies must be replaced. Refer to Section 7,
REPLACEMENT AND REPAIR.
8. REPLACEMENT AND REPAIR
Available separately, 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, tool assembly, and die assembly
through your representative, or call 1-800-526-5142,
or send a facsimile of your purchase order to
717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
9. REVISION SUMMARY
Revisions to this instruction sheet include:
•Updated document to corporate requirements
•New logo
Screwdriver
Lockscrew
RatchetAdjustment
Wheel
CRIMPING
CHAMBER
MARKING
MAXIMUM
WIRE SIZE
(AWG)
DIMENSION A
CRIMP HEIGHT
(mm [in.])
26-28 26 0.69±0.05 [.027±.002]
22-24 22 0.79±0.05 [.031±.002]
Position Point on
Center of Wire Barrel
Opposite Seam A
(See Table)

408-4007
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Rev D
Tooling Compatible with Die Assembly 90800-2
PRO-CRIMPER III Hand Tool Frame 354940-1
(Instruction Sheet 408-9930)
SDE-SA 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)
“C”-Head Assembly 2031450-1
With Shoulder Dies Only
(Instruction Sheet 408-10311)
Closed Head Assembly 2031460-1
With Pin Dies or Shoulder Dies
(Instruction Sheet 408-10312)
Electro-Hydraulic (BT 3500 Battery-Hydraulic)
Hand Tool Kits 2031400-[ ]
(Customer Manual 409-10095)