Tyco Electronics 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
The PRO-CRIMPER III Hand Crimping Tool is a “Commercial” grade tool and is designed
primarily for feild installation, repair, maintenance work, or prototyping in industrial,
commercial, or institutional applications. Product crimped with this tool will meet the crimp
height requirements for hand tools found in the appropriate 114 series specification, but may
not comply with other features or parameters of the specification. Tyco Electronics offers a
variety of tools to satisfy your performance requirements. For additional information, contact
the Tooling Assistance Center at 1-800-722-1111.
Ratchet
Adjustment
Wheeel
Moving Jaw
Die Assembly
Locator Assembly
(Supplied with Die 
Assembly)
Front of Tool
(Locator Side)
TE DIE
ASSEMBLY TE LOCATOR ASSEMBLY CONTACT FAMILY†
WIRE
SIZE
(AWG) INSULATION
DIAMETER STRIP LENGTH (mm IN.)
90872-2 58516-1 .093 Commercial
Pin and Socket 24-22 2.79 [.110] Max 3.96 to 4.72
[.156 to .186]
20-18
† Call the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION (see below) for 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
408-9967
PRO-CRIMPER* III Hand Crimping
Tool Assembly 90872-1 with
Die Assembly 90872-2 DEC 22 11 Rev D
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
90872-1 consists of Die Assembly 90872-2 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
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
Refer to Figure 1 and Figure 2.

Locator
Wire
Crimper
Offset
Wire Anvil Insulation
Anvil Chamfer
Insulation
Crimper
Locator
Assembly Tool Frame
Die Retaining Pins
Die Retaining Screws
Nut
Chamfer
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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.
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
1. Open the tool handles and remove the two die
retaining screws from the tool jaws. See 
Figure 2.
2. Place the wire anvil and insulation anvil so that
their chamfered sides and their marked surfaces
face outward, when mounted inthe 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. See Figure 2.
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.
9. 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.
10. Place the locator assembly over the end of
the long screw, and position the locator assembly
against the side of the tool jaw.
11. 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.
12. 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.

NOTE
i
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4. CONTACT SUPPORT ADJUSTMENT
Thecontact supportis preset priorto shipment,but
minor adjustment may be necessary. Refer to
Figure 3.

NOTE
i
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.


NOTE
i
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
asspecified inFigure 4. Referto 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.
Adjustment
Screw for
Contact 
Support
Contact Support Locator
Back of Tool
(Wire Side)
Wire
Contact
(Typ) Strip Length
Locator in
Wire Stop Slot Wire Inserted
to Stop
Figure 3

CAUTION
!
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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.
NOTE
i
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 wirein place, squeeze tool handles
together until the ratchet releases. Allow the tool
handles to open and remove crimped contact.
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. Tyco
Electronics does not manufacture or market crimp--
height comparators. Detailed information on obtaining
and using crimp--height comparators can befound in
instruction sheet 408-7424.
Wire Size
AWG (Max) Crimp Section (Wire Size Marking) Crimp Height Dim. “A”
22 24-22 .81
[.032]
18 20-18 1.02
[.040]
Position
Point on
Center of
Wire Barrel 
Opposite
Seam
Modified
Anvil ±.05 [.002]
Figure 4
Proceed as follows:
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)
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.
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 ADJUSTMENT.
7. RATCHET ADJUSTMENT
1. Remove the lockscrew from the ratchet
adjustment wheel. See Figure 5.
2. With a screwdriver, adjust the ratchet wheel
from the locator side 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.
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.
Figure 5

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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

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)
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)
Die Assembly 90872-2 Can Be Used in the Following Tools:
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T