TE Connectivity PRO-CRIMPER III User manual

Instruction Sheet
©2012 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
408-8739
PRO-CRIMPER* III Hand Crimping
Tool Assembly 91359-1 with
Die Assembly 91359-2 17 JAN 12 Rev B
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.
† Supplied with Die Assembly; Also Available Separately
‡ Contact PRODUCT INFORMATION at the number at the bottom of this page for specific contact part numbers
Figure 1
1. INTRODUCTION
PRO-CRIMPER III Hand Tool Assembly 91359-1
consists of PRO-CRIMPER III Hand Tool Frame
354940-5 and Die Assembly 91359-2. The tool
assembly is used to crimp the contacts onto the wire
listed in Figure 1. Read these instructions thoroughly
before using the tool assembly.
For additional information on the hand tool frame, refer
to 408-9930.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
2. DESCRIPTION (See Figure 1)
The tool consists of a tool frame with a stationary jaw,
stationary handle, moving jaw, and moving handle and
an adjustable ratchet that ensures full crimping. The
tool features a lower terminal support for supporting
the contact during crimping, and a ratchet adjustment
wheel for adjusting the crimp height.
Die Assembly
Moving Jaw
Ratchet Adjustment
Wheel
Stationary Jaw
Back of Tool Frame
(Wire Side)
Ratchet (Ref)
PRO-CRIMPER III Hand Tool
Frame 354940-5 (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.
Lower Terminal Support
Locator Assembly
Pivot Pin
DIE ASSEMBLY LOCATOR
ASSEMBLY † PRODUCT FAMILY ‡
WIRE
Size
(AWG)
Maximum Insulation
Diameter (mm [in.])
Strip Length
(mm [in.])
91359-2 58515-1
Electronic Control
Unit (ECU)-11
Generation II
18 2.36 [.093]
5.7 [.22]
16
(Fluoropolymer) 2.62 [.103]
NOTE
i
ORIGINAL INSTRUCTIONS

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Figure 2
The tool frame holds a die assembly that consists of a
wire anvil, insulation anvil, wire crimper, and insulation
crimper. When closed, the dies form two crimping
chambers. Die retaining pins and die retaining screws
are used to position and secure the dies in the tool
frame.
Attached to the outside of the frame is a locator
assembly, which contains a locator and contact retainer.
A nut is used on the upper die retaining screw to hold
the locator assembly in place.
3. INSTALLATION AND REMOVAL OF
DIE ASSEMBLY, LOCATOR ASSEMBLY, AND
LOWER TERMINAL SUPPORT (See 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 in the
moving jaws of the tool frame so that the chamfered
sides and marked surfaces face outward when
mounted.
3. Insert the two long die retaining pins through the
holes in the tool frame.
4. Insert the short die retaining screw through the
jaw and 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 in
the stationary jaw of the tool frame so that the
chamfered sides and marked surfaces face outward
when mounted.
6. Insert the two short die retaining pins through the
holes in the tool frame.
7. Insert the long die retaining screw through the
jaw and 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 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 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. Place the lower terminal support over the end of
the short die retaining screw, and position the lower
terminal support against the side of the tool jaw.
12. Place the nut onto the end of the short die
retaining screw, and tighten.
13. To disassemble, close the tool handles until the
ratchet releases, remove the nuts, the locator
assembly, the lower terminal support, the two die
retaining screws, and the four die retaining pins;
then, slide the anvils and crimpers out of the tool
jaws.
Long Die
Retaining Screw
Wire Anvil
Insulation
Anvil
Jaws
Short Die
Retaining Screw Long Die
Retaining Pins
Short Die
Retaining Pins
Nut
Nut
Locator Assembly
Lower
Terminal
Support
Chamfer
Offset
Insulation
Crimper
Wire
Crimper
Chamfer
Locator and
Contact Retainer

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4. CRIMPING PROCEDURE
This tool is provided with a contact support and a
crimp adjustment feature
. Initially, the contact
support should be checked as specified in
Paragraph 5.1, and the crimp and crimp height
should be verified as specified in Paragraph 5.2,
Ratchet Adjustment and Paragraph 6.3, Crimp
Height Inspection, and before using the tool.
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 die assembly. Refer to
Figure 3, and proceed as follows:
1. Squeeze the 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 appropriate crimping chamber.
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 barrel faces the top of the
tool. Place the contact up into the nest of the die so
that the locator drops into the wire stop slot in the
contact. Refer to Figure 3. Butt the front end of the
wire barrel against the locator. Make sure that the
wire stop enters the contact wire stop slot between
the wire barrel and contact shoulder.
Make sure that both sides of the contact insulation
barrel are started evenly into the crimping chamber.
Do not attempt to crimp an improperly positioned
contact.
4. Hold the contact in place, 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 the stripped wire into the contact insulation
barrel and wire barrel until it butts against the wire
stop as shown in Figure 3.
DO NOT use defective or damaged products.
5. TOOL ADJUSTMENTS
5.1. Contact Support Adjustment
The contact support is preset prior to shipment, but
minor adjustment may be necessary.
Make a sample crimp and determine if the contact is
straight. If the contact is bending upward or downward,
make an adjustment as follows:
1. 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.
2. Place a contact and 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.
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, and close the handles until the
ratchet releases.
Figure 3
NOTE
i
!
CAUTION
!
CAUTION
NOTE
i
NOTE
i
Strip Length
Contact (Ref)
Lower Terminal
Support
Locator in Contact
Wire Stop Slot
Wire
Dies
Back (Wire Side)
of Tool
Wire
Contact Insulation
Barrel
Nest

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6. Remove and inspect the contact.
7. 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.
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. MAINTENANCE AND INSPECTION
6.1. 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.
3. Remove all lubrication and accumulated film from
the dies by immersing the dies in a suitable
commercial degreaser.
6.2. 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.
6.3. 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. Refer to
instruction sheet 408-7424 for detailed information on
obtaining and using a crimp height comparator.
Inspect the crimp height as follows:
1. Refer to Figure 5, and select a maximum size
wire for each crimping chamber as listed.
2. Crimp the contact according to Section 3,
CRIMPING PROCEDURE.
3. Using the crimp height comparator, measure the
wire barrel crimp height as shown in Figure 5. If the
crimp height conforms to the dimensions provided,
the tool is considered dimensionally correct. If the
crimp height does not conform to the dimensions
provided, the tool must be adjusted. Refer to
Paragraph 5.2, Ratchet Adjustment.
Figure 5
Screwdriver
Lockscrew
RatchetAdjustment
Wheel
WIRE SIZE
(AWG)
CRIMPING CHAMBER
MARKING
CRIMP HEIGHT
DIMENSION A
±0.05 mm [±.002 in.]
(mm [in.])
18 18 1.37 [.054]
16 16 (Fluoropolymer) 1.50 [.059]
A
Note: Not to Scale
Point on Center
of Wire Barrel
Opposite Seam
Modified
Anvil

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7. REPLACEMENT AND REPAIR
Customer-replaceable parts are shown in Figure 1.
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
8. REVISION SUMMARY
Revisions to this instruction sheet include:
•Changed company name and logo
•Added ORIGINAL INSTRUCTIONS to first page
•Replaced trademark with general term in Figures
1 and 4
•Updated tool compatibility on last page

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Tooling Compatible with Die Assembly 91359-2
SDE-SA Hand Tool 9-1478240-0
(Instruction Sheet 408-8851)
PRO-CRIMPER III Hand Tool Frame 354940-1
(Instruction Sheet 408-9930)
SDE Bench Terminator 1490076-2
(Customer Manual 409-10052)
626 Adapter 679304-1
(Instruction Sheet 408-4070)
Electro-Hydraulic (BT 3500 Battery-Hydraulic)
Hand Tool Kits 2031400-[ ]
(Customer Manual 409-10095)
“C”-Head Assembly 2031450-1
(Instruction Sheet 408-10311)
Closed Head Assembly 2031460-1
(Instruction Sheet 408-10312)