TE Connectivity PRO-CRIMPER III User manual

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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.
Instruction Sheet
408-9884
10 APR 15 Rev D
DIE ASSEMBLY
PRODUCT FAMILY‡
WIRE SIZE
PART NUMBER
LOCATOR
ASSEMBLY†
SIZE (AWG)
INSULATION
DIAMETER
STRIP LENGTH
90547-2
58515-1
Universal MATE-N-LOK*
Contacts
20-18
3.30 to 5.08
[.130 to .200]
3.96 to 4.75
[.156 to .187]
16-14
†Supplied with die assembly. Also available separately.
‡Call one of the numbers at the bottom of this page for contact part numbers.
Figure 1
1. INTRODUCTION
This tool assembly is used to crimp the contacts onto the wires listed in Figure 1.
2. DESCRIPTION
Tool features are shown in Figure 1.
NOTE
Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale.
Reasons for re-issue of this instruction sheet are provided in Section 10, REVISION SUMMARY.
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY
1. Close the tool handles until the ratchet releases, then allow the handles to open fully.
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.
PRO-CRIMPER* III Hand Crimping
Tool Assembly 90547-1 with
Die Assembly 90547-2
Stationary Jaw
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 Assembly
Moving Jaw
Die Retaining Screw
(2 Places)
Ratchet Adjustment
Wheel
Pivot Pin
Back of Tool Frame
(Wire Side)
Ratchet
PRO-CRIMPER III Hand Tool
Frame 354940-1 (408-9930)
Stationary Handle
Moving Handle
Locator Assembly

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Figure 2
2. Remove the two die retaining screws from the tool jaws.
3. Place the wire anvil and insulation anvil in the moving jaw of the tool frame as shown in Figure 2.
4. Insert two die retaining pins into the moving jaw.
5. Insert the short die retaining screw through the jaw and through the anvils, and thread the screw just
enough to hold the anvils in place. Do not tighten the screw at this time.
6. Place the wire crimper and insulation crimper in the stationary jaw of the tool frame as shown in
Figure 2.
7. Insert two die retaining pins into the stationary jaw.
8. Insert the long die retaining screw through the jaw and through the crimpers, and thread the screw just
enough to hold the crimpers in place. Do not tighten the screw at this time.
9. Carefully close the tool handles, making sure that the anvils and crimpers align properly. Continue
closing the tool handles until the ratchet has engaged sufficiently to hold the anvils and crimpers in
place, then tighten both die retaining screws.
10. 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.
11. Place the nut onto the end of the screw, and tighten the nut enough to hold the locator assembly in
place, while still allowing the locator to slide up and down.
12. To disassemble, close the tool handles until the ratchet releases, remove the nut, the locator assembly,
die retaining screws, and die retaining pins, then slide the anvils and crimpers out of the tool jaws.
4. CONTACT SUPPORT ADJUSTMENT
NOTE
The contact support is preset prior to shipment, but minor adjustment may be necessary.
1. Crimp a sample according to Section 5 and determine if the contact is straight, bending upward, or
bending downward. If adjustment is required (contact is bent), loosen the screw that holds the contact
support onto the locator assembly. Refer to Figure 3.
2. Place a contact with wire into the proper nest of the tool, and close the tool handles until the ratchet
reaches the sixth click or until the contact support touches the contact.
NOTE
The ratchet has detents that create audible clicks as the tool handles are closed.
Insulation
Crimper
Short Die
Retaining Screw
Stationary Die
Retaining Pins
Nut
Locator
Locator Assembly
Chamfer (Ref)
Wire Anvil
Insulation Anvil
Wire Crimper
Offset (Ref)
Chamfer (Ref)
Tool Frame
Long Die
Retaining Screw
Moving Die
Retaining Pins
Stationary
Jaw
Moving
Jaw

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Figure 3
3. Slightly loosen the nut that holds the locator assembly onto the tool frame.
4. Move the contact support as required to eliminate the bending of the contact.
5. Tighten the nut, then close the tool handles until the ratchet releases.
6. Remove and inspect the contact.
7. Crimp another sample. 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
Before using the tool, the contact crimp height should be verified as described in Section 5.
1. Refer to Figure 1, and select a contact for the wire size being used. Strip the wire to the length
indicated in Figure 1, taking care not to nick or cut wire strands. Identify the appropriate crimping
chamber according to the wire size markings on the tool.
2. Close the tool handles until the ratchet releases, then allow the handles to open fully.
3. Holding the contact by the mating end and so that the open “U”of the wire barrel faces the top of the
tool, insert the contact—insulation barrel first—into the appropriate crimping chamber from the front of
the tool. Position the contact up into the nest so that the locator drops into the slot in the contact. See
Figure 3. Move the front end of the wire barrel against the locator.
CAUTION
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 squeeze the tool handles together until the ratchet engages
sufficiently to hold the contact in position. Do not deform the wire barrel or insulation barrel.
5. Insert the stripped wire into the wire barrel until it butts against the wire stop as shown in Figure 3.
6. Holding the wire in place, squeeze the tool handles together until the ratchet releases, then allow the
handles to open. Remove the crimped contact.
NOTE
The crimped contact may stick in the crimping area, but the contact can be easily removed by pushing down on the top of the
locator.
7. Check the contact crimp height as described in Section 6. If necessary, adjust the crimp height as
described in Section 7.
Contact
Support
Wire (Contact
Not Shown)
Locator
Back of Tool
(Wire Side)
Adjustment Screw
for Contact Support
Contact
(Typ)
Strip Length (Ref)
Note: Not to Scale
Locator in
Contact
Wire Stop Slot
Wire Inserted
to Stop

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6. CRIMP HEIGHT INSPECTION
1. Refer to Figure 4, and select a maximum size wire for each crimping chamber.
2. Crimp the contact(s).
3. Using a crimp height comparator, measure the crimp height as shown in Figure 4. If the crimp height
conforms, the tool is considered dimensionally correct. If not, the tool must be adjusted. Refer to
Section 7.
NOTE
Detailed information on obtaining and using crimp height comparators can be found in instruction sheet 408-7424.
Figure 4
7. RATCHET ADJUSTMENT
1. Remove the lockscrew from the ratchet adjustment wheel. Refer to Figure 5.
2. Using a screwdriver, adjust the ratchet adjustment wheel. If a tighter crimp is required, rotate the
wheel counterclockwise to a higher-numbered setting. If a looser crimp is required, rotate the wheel
clockwise to a lower-numbered setting.
3. Re-install the lockscrew.
4. Make a sample crimp. If the crimp is acceptable, the adjustment setting is correct. If the crimp is
unacceptable, continue to adjust the ratchet adjustment wheel and measure a sample crimp.
Figure 5
8. TOOL MAINTENANCE AND INSPECTION
8.1. 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.
Screwdriver
Ratchet Adjustment
Wheel
Lockscrew
Point on Center
of Wire Barrel
Opposite Seam
MAXIMUM
WIRE SIZE
(AWG)
CRIMPING CHAMBER
(Wire Size Marking)
CRIMP HEIGHT
18 20-18
1.24±0.05
[.049±.002]
14 16-14
1.60±0.05
[.063±.002]
Modified Anvil
Crimp Height
(Refer to
Table)

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3. Remove all lubrication and accumulated film from the dies by immersing the dies in a suitable
commercial degreaser.
8.2. 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 9.
9. 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 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
10. REVISION SUMMARY
Revisions to this instruction sheet include:
Changed company name and logo

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Tooling Compatible with Die Assembly 90547-2
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)
Battery Tool (Shouldered Die) 1725837-1 and -2
(Customer Manual 409-10053)
Battery Tool (Pin Die) 1213890-1 and -2
(Customer Manual 409-10065)