Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 90872-1 with 408-9967 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. Locator Assembly Stationary Jaw (Supplied with Die  Assembly) Back of Tool (Wire Side) Front of Tool (Locator Side) Pivot Pin Die Assembly Moving Jaw PRO-CRIMPER III Hand Crimping Tool Frame 354940-1 (408-9930) Ratchet Adjustment Wheeel Stationary 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, Moving commercial, or institutional applications. Product crimped with this tool will meet the crimp Handle 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. WIRE TE DIE TE LOCATOR CONTACT SIZE INSULATION STRIP LENGTH ASSEMBLY ASSEMBLY FAMILY† (AWG) DIAMETER (mm IN.) 24-22 .093 Commercial 3.96 to 4.72 90872-2 58516-1 2.79 [.110] Max Pin and Socket [.156 to .186] 20-18 † Call the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION (see below) for part numbers. Figure 1 Dimensions on this sheet are in millimeters [with 1. INTRODUCTION NOTE inch equivalents provided in brackets]. Figures and PRO-CRIMPER III Hand Crimping Tool Assembly illustrations are for identification only and are not i 90872-1 consists of Die Assembly 90872-2 and  drawn to scale. PRO-CRIMPER III Hand Crimping Tool Frame Reasons for reissue are provided in Section 11, 354940-1. The die assembly consists of crimping dies REVISION SUMMARY. and a locator assembly. Read these instructions thoroughly before crimping 2. DESCRIPTION any contacts. Refer to Figure 1 and Figure 2. © 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. 408-9967 Locator Assembly Nut Tool Frame Locator Insulation Die Retaining Pins Chamfer Crimper Wire Crimper Offset Wire Anvil Insulation Chamfer Die Retaining Screws Anvil Figure 2 The tool features a tool frame with a stationary jaw 5. Place the wire crimper and insulation crimper and handle, a moving jaw, a moving handle, and an so that their chamfered sides and their marked adjustable ratchet that ensures full contact crimping. surfaces face outward, when mounted in the stationary jaw of the tool frame. The tool frame holds a die assembly with two crimping sections. 6. Insert the two die retaining pins. See Figure 2. The die assembly features a wire anvil, an insulation 7. Insert the long die retaining screw through the anvil, a wire crimper, and an insulation crimper. jaw and through both crimper dies, and tighten Attached to the outside of the frame is a locator the screw just enough to hold the dies in place. assembly, which contains a locator, a spring retainer, Do not tighten the screw completely at this time. and a contact support. 8. Carefully close the tool handles, making sure Die retaining pins and die retaining screws are used to that the anvils and crimpers align properly. position and secure the dies in the tool frame. A nut is 9. Continue closing the tool handles until the used on the upper die retaining screw to hold the ratchet in the tool frame has engaged sufficiently locator assembly in place. to hold the anvils and crimpers in place, then tighten both die retaining screws. 3. INSTALLATION AND REMOVAL OF DIE SET AND LOCATOR ASSEMBLY 10. Place the locator assembly over the end of the long screw, and position the locator assembly 1. Open the tool handles and remove the two die against the side of the tool jaw. retaining screws from the tool jaws. See  Figure 2. 11. Place the nut onto the end of the long screw and tighten the nut enough to hold the locator 2. Place the wire anvil and insulation anvil so that assembly in place, while still allowing the locator their chamfered sides and their marked surfaces to slide up and down. face outward, when mounted in the moving jaw of the tool frame. 12. To disassemble, close the tool handles until the ratchet releases, remove the nut, the locator 3. Insert the two die retaining pins. assembly, the two die retaining screws, and the 4. Insert the short die retaining screw through the four die retaining pins, and slide the anvils and jaw and through both anvil dies, and tighten the crimpers out of the tool jaws. screw just enough to hold the dies in place. Do not tighten the screw completely at this time. Rev D 2 of 6 408-9967 4. CONTACT SUPPORT ADJUSTMENT contact is still being bent during crimping, repeat the adjustment procedure. The contact support is preset prior to shipment, but NOTE minor adjustment may be necessary. Refer to 5. CRIMPING PROCEDURE Figure 3. i This tool is provided with a crimp adjustment NOTE feature. Initially, the crimp height should be verified 1. Make a sample crimp and determine if the as specified in Figure 4. Refer to Section 6, CRIMP i contact is straight, bending upward, or bending HEIGHT INSPECTION, and Section 7, RATCHET downward. ADJUSTMENT, to verify crimp height before using the tool to crimp desired contacts and wire sizes. 2. If adjustment is required, loosen the screw that holds the contact support onto the locator Refer to the table in Figure 1 and select wire of the assembly. specified size and insulation diameter. Strip the wire to the length indicated in Figure 1, taking care not to nick The ratchet has detents that create audible clicks NOTE or cut wire strands. Select an applicable contact and as the tool handles are closed. identify the appropriate crimp section according to the  i wire size markings on the tool. Refer to  Figure 3 and proceed as follows: 3. Place a contact with wire into the proper nest 1. Hold the tool so that the back (wire side) is and close the tool handles until the ratchet facing you. Squeeze tool handles together and reaches the sixth click, or until the contact allow them to open fully. support touches the contact. 2. Holding the contact by the mating end, insert 4. Slightly loosen the nut that holds the locator the contact — insulation barrel first — through the assembly onto the tool frame. front of the tool and into the appropriate crimp section. 5. Move the contact support as required to eliminate the bending of the contact. 3. Position the contact so that the mating end of the contact is on the locator side of the tool, and so that 6. Tighten the nut and close the handles until the the open “U” of the wire and insulation barrels face ratchet releases. the top of the tool. Place the contact up into the nest 7. Remove and inspect the contact. so that the movable locator drops into the slot in the contact. Refer to Figure 3. Butt the front end of the 8. Make another sample crimp. If the contact is wire barrel against the movable locator. straight, tighten the contact support screw. If the Locator Contact Support Back of Tool (Wire Side) Adjustment Screw for Contact  Support Contact Strip Length (Typ) Wire Locator in Wire Inserted Wire Stop Slot to Stop Figure 3 Rev D 3 of 6 408-9967 Make sure that both sides of the insulation barrel Proceed as follows: CAUTION are started evenly into the crimping section. Do 1. Refer to Figure 4 and select a wire (maximum NOT attempt to crimp an improperly positioned ! size) for each crimp section listed. contact. 2. Refer to Section 5, CRIMPING PROCEDURE, 4. Hold the contact in position and squeeze the and crimp the contact(s) accordingly. tool handles together until ratchet engages sufficiently to hold the contact in position. Do 3. Using a crimp height comparator, measure the NOT deform insulation barrel or wire barrel. wire barrel crimp height as shown in Figure 4. If the crimp height conforms to that shown in the 5. Insert stripped wire into contact insulation and table, the tool is considered dimensionally wire barrels until it is butted against the wire stop, correct. If not, the tool must be adjusted. Refer to as shown in Figure 3. Section 7, RATCHET ADJUSTMENT. 6. Holding the wire in place, squeeze tool handles 7. RATCHET ADJUSTMENT together until the ratchet releases. Allow the tool handles to open and remove crimped contact. 1. Remove the lockscrew from the ratchet adjustment wheel. See Figure 5. The crimped contact may stick in the crimping area, NOTE but the contact can be easily removed by pushing 2. With a screwdriver, adjust the ratchet wheel downward on the top of the locator (see Figure 3). from the locator side of the tool. i  3. Observe the ratchet adjustment wheel. If a tighter crimp is required, rotate the adjustment 7. Check the contact’s crimp height as described wheel COUNTERCLOCKWISE to a higher- in Section 6, CRIMP HEIGHT INSPECTION. If numbered setting. If a looser crimp is required, necessary, adjust the crimp height as described rotate the adjustment wheel CLOCKWISE to a in Section 7, RATCHET ADJUSTMENT. lower-numbered setting. 6. CRIMP HEIGHT INSPECTION 4. Replace the lockscrew. Crimp height inspection is performed through the use 5. Make a sample crimp and measure the crimp of a micrometer with a modified anvil, commonly height. If the dimension is acceptable, replace referred to as a crimp--height comparator. Tyco and secure the lockscrew. If the dimension is Electronics does not manufacture or market crimp-- unacceptable, continue to adjust the ratchet, and height comparators. Detailed information on obtaining again measure a sample crimp. and using crimp--height comparators can befound in instruction sheet 408-7424. Screwdriver Position Point on Center of Wire Barrel  Opposite Seam Ratchet Modified Adjustment ±.05 [.002] Anvil Wheel Lockscrew Wire Size Crimp Section Crimp Height AWG (Max) (Wire Size Marking) Dim. “A” (Typ) .81 22 24-22 [.032] Figure 5 1.02 18 20-18 [.040] Figure 4 Rev D 4 of 6 408-9967 8. MAINTENANCE 10. REPLACEMENT Ensure that the tool and dies are clean by wiping them Customer-replaceable parts are shown in Figure 1. with a clean, soft cloth. Remove any debris with a Available separately, PRO-CRIMPER III Hand clean, soft brush. Do not use objects that could Crimping Tool Repair Kit 679221-1 includes a damage the tool. When not in use, keep handles replacement nut and a variety of pins, rings, screws, closed to prevent objects from becoming lodged in the and springs. If the dies are damaged or worn crimping dies, and store in a clean, dry area. excessively, they must be replaced. 9. VISUAL INSPECTION Order the repair kit and replaceable parts through your TE representative, or call 1-800-526-5142, or send a The crimping dies should be inspected on a regular facsimile of your purchase order to 1-717-986-7605, or basis to ensure that they have not become worn or write to damaged. Inspect the crimp sections for flattened, chipped, worn, or broken areas. If damage or CUSTOMER SERVICE (038-035) abnormal wear is evident, the tool must be replaced. TYCO ELECTRONICS CORPORATION See Section 10, REPLACEMENT. PO BOX 3608 HARRISBURG PA 17105-3608 11. REVISION SUMMARY Revisions to this instruction sheet include: • Changed company name and logo Rev D 5 of 6 408-9967 T Die Assembly 90872-2 Can Be Used in the Following Tools: PRO-CRIMPER III Hand Tool Frame 354940-1 SDE-SA Hand Tool 9-1478240-0 (Instruction Sheet 408-9930) (Instruction Sheet 408-8851) SDE Bench Terminator 1490076-2 626 Adapter 679304-1 (Customer Manual 409-10052) (Instruction Sheet 408-4070) Electro-Hydraulic (BT 3500 Battery-Hydraulic) Closed Head Assembly 2031460-1 “C”-Head Assembly 2031450-1 Hand Tool Kits 2031400-[ ] (Instruction Sheet 408-10312) (Instruction Sheet 408-10311) (Customer Manual 409-10095) Rev D 6 of 6