Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 90871-1 408-9966 with Die Assembly 90871-1 and -2 13 OCT 11 Rev C 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 Stationary Jaw Back of Tool (Supplied with Die Assembly) (Wire Side) Front of Tool Pivot Pin (Locator Side) Die Assembly PRO-CRIMPER III Hand Crimping Tool Frame 354940-1  (408-9930) Stationary Moving Jaw Handle Ratchet Adjustment Wheel Moving Handle WIRE TE DIE TE LOCATOR CONTACT ASSEMBLY ASSEMBLY† FAMILY‡ SIZE (AWG) INSUL DIA STRIP LENGTH 20-18 .093 Commercial 3.96 to 4.72 90871-2 58516-1 3.56 [.140] Max Pin and Socket [.156 to .186] 16-14 † 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 2. DESCRIPTION (Figure 1 and Figure 2) PRO-CRIMPER III Hand Crimping Tool Assembly The tool features a tool frame with a stationary jaw 90871-1 consists of Die Assembly 90871-2 and PRO- and handle, a moving jaw, a moving handle, and an CRIMPER III Hand Crimping Tool Frame 354940-1. adjustable ratchet that ensures full contact crimping. The die assembly consists of crimping dies and a The tool frame holds a die assembly with two crimping locator assembly. sections. Read these instructions thoroughly before crimping The die assembly features a wire anvil, an insulation any contacts. anvil, a wire crimper, and an insulation crimper. Dimensions on this sheet are in millimeters [with Attached to the outside of the frame is a locator NOTE inch equivalents provided in brackets]. Figures and assembly, which contains a locator, a spring retainer, illustrations are for identification only and are not and a contact support. i drawn to scale. Reasons for reissue are provided in Section 11, REVISION SUMMARY. © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-9966 Locator Nut Tool Frame Assembly Locator Die Retaining Pins Chamfer Insulation Crimper Wire Crimper Offset Wire Anvil Die Retaining Insulation Die Retaining Chamfer Screw Anvil Screw Figure 2 Die retaining pins and die retaining screws are used to 8. Carefully close the tool handles, making sure that position and secure the dies in the tool frame. A nut is the anvils and crimpers align properly. Continue used on the upper die retaining screw to hold the closing the tool handles until the ratchet in the tool locator assembly in place. frame has engaged sufficiently to hold the anvils and crimpers in place, then tighten both die retaining screws. 3. INSTALLATION AND REMOVAL OF DIE SET AND LOCATOR ASSEMBLY (Figure 2) 9. Place the locator assembly over the end of the 1. Open the tool handles and remove the two die long screw, and position the locator assembly retaining screws from the tool jaws. against the side of the tool jaw. 2. Place the wire anvil and insulation anvil so that 10. Place the nut onto the end of the long screw and their chamfered sides and their marked surfaces tighten the nut enough to hold the locator assembly face outward, when mounted in the moving jaw of in place, while still allowing the locator to slide up the tool frame. and down. 3. Insert the two die retaining pins. 11. To disassemble, close the tool handles until the ratchet releases, remove the nut, the locator 4. Insert the short die retaining screw through the assembly, the two die retaining screws, and the four jaw and through both anvil dies, and tighten the die retaining pins, and slide the anvils and crimpers screw just enough to hold the dies in place. Do not out of the tool jaws. tighten the screw completely at this time. 5. Place the wire crimper and insulation crimper so 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) that their chamfered sides and their marked The contact support is preset prior to shipment, but NOTE surfaces face outward, when mounted in the minor adjustment may be necessary. stationary jaw of the tool frame. i 6. Insert the two die retaining pins. 7. Insert the long die retaining screw through the 1. Make a sample crimp and determine if the jaw and through both crimper dies, and tighten the contact is straight, bending upward, or bending screw just enough to hold the dies in place. Do not downward. tighten the screw completely at this time. 2. If adjustment is required, loosen the screw that holds the contact support onto the locator assembly. Rev C 2 of 6 408-9966 The ratchet has detents that create audible clicks Adjustment, to verify crimp height before using the NOTE as the tool handles are closed. tool to crimp desired contacts and wire sizes. i 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 3. Place a contact with wire into the proper nest and identify the appropriate crimp section according to the close the tool handles until the ratchet reaches the wire size markings on the tool. Refer to Figure 3 and sixt# click, or until the contact support touches the proceed as follows: contact. 1. Hold the tool so that the back (wire side) is facing 4. Slightly loosen the nut that holds the locator you. Squeeze tool handles together and allow them assembly onto the tool frame. to open fully. 5. Move the contact support as required to eliminate 2. Holding the contact by the mating end, insert the the bending of the contact. contact - insulation barrel first - through the front of 6. Tighten the nut and close the handles until the the tool and into the appropriate crimp section. ratchet releases. 3. Position the contact so that the mating end of the 7. Remove and inspect the contact. contact is on the locator side of the tool, and so that the open "U" of the wire and insulation barrels face 8. Make another sample crimp. If the contact is the top of the tool. Place the contact up into the nest straight, tighten the contact support screw. If the so that the movable locator drops into the slot in the contact is still being bent during crimping, repeat the contact. Refer to Figure 3. Butt the front end of the adjustment procedure. wire barrel against the movable locator. 5. CRIMPING PROCEDURE Make sure that both sides of the insulation barrel CAUTION This tool is provided with a crimp adjustment are started evenly into the crimping section. Do not NOTE feature. Initially, the crimp height should be verified attempt to crimp an improperly positioned contact. ! as specified in Figure 4. Refer to Section 6, Crimp i Height Inspection, and Section 7, RATCHET Contact Locator Support Adjustment Screw for Contact Support Back of Tool (Wire Side) Contact (Typ) Strip Length Locator Wire in Wire Inserted Stop Slot to Stop Wire Figure 3 Rev C 3 of 6 408-9966 4. Hold the contact in position and squeeze the tool 3. Using a crimp height comparator, measure the handles together until ratchet engages sufficiently to wire barrel crimp height as shown in Figure 4. If the hold the contact in position. Do NOT deform crimp height conforms to that shown in the table, insulation barrel or wire barrel. the tool is considered dimensionally correct. If not, the tool must be adjusted. Refer to Section 7, 5. Insert stripped wire into contact insulation and RATCHET (Crimp Height) ADJUSTMENT. wire barrels until it is butted against the wire stop, as shown in Figure 3. 7. RATCHET (Crimp Height) ADJUSTMENT (Figure 5) 6. Holding the wire in place, squeeze tool handles 1. Remove the lockscrew from the ratchet together until ratchet releases. Allow tool handles to adjustment wheel. open and remove crimped contact. 2. With a screwdriver, adjust the ratchet wheel from The crimped contact may stick in the crimping area, NOTE the locator side of the tool. but the contact can be easily removed by pushing downward on the top of the locator (see Figure 3). i Screwdriver 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. Ratchet Detailed information on obtaining and using crimp- Adjustment height comparators can be found in instruction sheet Wheel 408-7424. Proceed as follows: 1. Refer to Figure 4 and select a wire (maximum Lockscrew size) for each crimp section listed. (Typ) 2. Refer to Section 5, CRIMPING PROCEDURE, and crimp the contact(s) accordingly. Figure 5 Position Point 3. Observe the ratchet adjustment wheel. If a tighter on Center of crimp is required, rotate the adjustment wheel Wire Barrel COUNTERCLOCKWISE to a higher-numbered Opposite setting. If a looser crimp is required, rotate the Seam adjustment wheel CLOCKWISE to a lower- numbered setting. Modified Anvil 4. Replace the lockscrew. 5. Make a sample crimp and measure the crimp height. If the dimension is acceptable, replace and WIRE SIZE CRIMP SECTION CRIMP HEIGHT secure the lockscrew. If the dimension is AWG (Max) (Wire Size Marking) DIMENSION “A” unacceptable, continue to adjust the ratchet, and 18 20-18 1.07 [.042] again measure a sample crimp. 14 16-14 1.45 [.057] Figure 4 Rev C 4 of 6 408-9966 8. MAINTENANCE Available separately, PRO-CRIMPER III Hand Crimping Tool Repair Kit 679221-1 includes a Ensure that the tool and dies are clean by wiping them replacement nut and a variety of pins, rings, screws, with a clean, soft cloth. Remove any debris with a and springs. clean, soft brush. Do not use objects that could damage the tool. When not in use, keep handles If the dies are damaged or worn excessively, they closed to prevent objects from becoming lodged in the must be replaced. crimping dies, and store in a clean, dry area. Order the repair kit and replaceable parts through your TE representative, or call 1-800-526-5142, or send a 9. VISUAL INSPECTION facsimile of your purchase order to 1-717-986-7605, or The crimping dies should be inspected on a regular write to: basis to ensure that they have not become worn or damaged. Inspect the crimp sections for flattened, CUSTOMER SERVICE (038-035) chipped, worn, or broken areas. If damage or TYCO ELECTRONICS CORPORATION abnormal wear is evident, the tool must be replaced. PO BOX 3608 See Section 10, REPLACEMENT. HARRISBURG PA 17105-3608 11. REVISION SUMMARY 10. REPLACEMENT Revisions to this instruction sheet include: Customer-replaceable parts are shown in Figure 1. • Changed company name and logo Rev C 5 of 6 408-9966 Tooling Used With 90871-2 Rev C 6 of 6