TE Connectivity PRO-CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand
Crimping Tool Assembly 90869- 1 408--9964
LOC B
1of 6
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks.
*Trademark. Other logos, product and/or Company names may be trademarks of their respective owners.
TOOLING ASSISTANCE CENT ER 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
21 Mar 11 Rev Dwith Die Assembly 90869- 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.
Locator Assembly
(Supplied with
Die Assembly)
Ratchet
Adjustment
Wheel
Moving Jaw
Die Assembly
Front of Tool
(Locator Side)
Stationary Jaw
Back of Tool
(Wire Side)
Pivot Pin
PRO--CRIMPER III Hand
Crimping 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 114 series specification, 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.
T
E
D
i
e
A
s
s
e
m
b
l
y
TE Locator Contact Wire
T
E
D
i
e
A
ssem
b
l
y
T
E
L
o
c
a
t
o
r
Assembly{
C
o
n
t
a
c
t
Family}Size (AWG) Insul Dia Strip Length
9
0
8
6
9
2
5
8
5
1
6
1
.062 Commercial 24--22 1.27 -- 2.79 3.05 + 0.38
90869--2 58516--1 .
0
6
2
C
o
m
m
e
r
c
i
a
l
Pin and Socket 20--18
1
.
2
7
2
.
7
9
[.050 -- .110]
3
.
0
5
+
0
.
3
8
[.120 + .015]
{Supplied with die assembly. Also available separately.
}Contact the Tooling Assistance Center or Product Information (see below) for specific contact part numbers.
Figure 1
1. INTRODUCTION
PRO--CRIMPER III Hand Crimping Tool
Assembly 90869--1 consists of Die Assembly
90869--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.
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.
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 two
crimping sections.
The die assembly features a wire anvil, an insulation
anvil, a wire crimper, and an insulation crimper.
NOTE
i

408- 9964
Rev D2 of 6
Figure 2
Nut
Locator
Chamfer
Wire Crimper
Offset
Wire Anvil Insulation
Anvil
Chamfer
Locator
Assembly Tool Frame
Die Retaining
Pins
Die Retaining
Screws
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- 9964
3of 6Rev D
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 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.
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.
Figure 3
Contact
Support
Locator
Adjustment
Screw for
Contact
Support
Back of Tool
(Wire Side)
Wire Locator
in Wire
Stop Slot Wire
Inserted
to Stop
Contact
(Typ)
Strip
Length
NOTE
i
NOTE
i
NOTE
i
CAUTION
!

408- 9964
Rev D4 of 6
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 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.
Position Point
on Center of
Wire Barrel
Opposite
Seam
“A”
Modified Anvil
Wire Size Crim
p
Section Crimp Height
D
i
m
e
n
s
i
o
n
A
W
i
r
e
S
i
z
e
AWG (Max)
C
r
i
m
p
S
e
c
t
i
o
n
(Wire Size Marking) Dimension A
+.051 [+.002]
22 24--22 0.81 [.032]
18 20--18 0.99 [.039]
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.
Figure 5
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)
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.
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.
NOTE
i

408- 9964
5of 6Rev D
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:
SUpdated document to corporate requirements.

408- 9964
Rev D6 of 6
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)
Tooling Used With Dies 90869-2