TE Connectivity PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

*Trademark

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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

PRO-CRIMPER* III Hand Crimping

Tool Assembly 90800-1 with

Die Assembly 90800-2 408-4007

19 APR 11 Rev D

Figure 1

1. INTRODUCTION

PRO-CRIMPER III Hand Tool Assembly 90800-1

consists of PRO-CRIMPER III Hand Tool Frame

354940-1 and Die Assembly 90800-2. The tool

assembly is used to crimp the contacts given in

Figure 1,

Read these instructions thoroughly before using the

tool assembly.

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Figures are not drawn to scale.

For additional information on the hand tool frame, refer

to 408-9930.

Reasons for reissue of this instruction sheet are

provided in Section 9, REVISION SUMMARY.

2. DESCRIPTION (See Figure 1)

The tool consist of a stationary jaw and handle, a

moving jaw and handle, and an adjustable ratchet that

ensures full crimping. The tool features a ratchet

adjustment wheel for adjusting the crimp height.

A locator assembly is attached to the tool frame and

consists of a locator, spring retainer, and contact

support.

The contact support prevents the contact from

bending during crimping. A nut used on the long die

retaining screw holds the locator assembly in place.

The die assembly consists of two anvil dies (wire and

insulation) and two crimper dies (wire and insulation).

DIE ASSEMBLY LOCATOR

ASSEMBLY PRODUCT FAMILY

WIRE

SIZE RANGE

(AWG)

INSULATION

DIAMETER

(mm [in.])

STRIP LENGTH

(mm [in.])

90800-2 58516-1 AMPLIMITE* HD

Crimp-Snap Contacts 28-22 0.76-1.02

[.030-.040]

3.56-3.96

[.140-.156]

NOTE

Die Assembly

Moving Jaw

Ratchet Adjustment

Wheel

Stationary Jaw

Back of Tool Frame

(Wire Side)

Pivot Pin

Ratchet

PRO-CRIMPER III Hand 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 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 Retaining Screw

(2 Places)

Locator Assembly

(Supplied with Die Assembly)

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.

ORIGINAL INSTRUCTIONS

408-4007

2of 5

Rev D

Figure 2

When closed, the dies form two crimping chambers.

Each die is held in the tool frame by a retaining screw

and two retaining pins.

3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY

AND LOCATOR ASSEMBLY

1. Close the tool handles until the ratchet releases,

then allow the handles to open fully.

2. Remove the two die retaining screws from the

tool jaws.

3. Slide the wire anvil and insulation anvil dies onto

the moving jaw so that the chamfers and marked

surfaces face outward as shown in Figure 2, then

insert the two die retaining pins through the holes in

the moving jaw and into the holes in the dies.

4. Thread, but do not tighten, the short die retaining

screws through the holes of the moving jaw and into

the holes in both anvil dies.

5. S

lide the wire crimper and insulation crimper dies

onto the stationary jaw so that the chamfers and

marked surfaces face outward as shown in Figure 2,

then insert the two die retaining pins through the holes

in the stationary jaw and into the holes in the dies.

6. Thread, but do not tighten, the long die retaining

screws through the holes of the moving jaw and into

the holes in both crimper dies.

7. Carefully close the tool handles, making sure that

the dies align properly. Continue closing the

handles until the ratchet has engaged sufficiently to

hold the dies in place.

8. Tighten the die retaining screws using the

appropriate screwdriver.

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. To disassemble, close the tool handles until the

ratchet releases. Remove the nut, locator assembly,

the two die retaining screws, and four die retaining

pins, then, slide the dies out of the tool jaws.

4. CRIMPING PROCEDURE

The tool frame is provided with a crimp adjustment

feature. Initially, the crimp height should be verified

according to Section 6, CRIMP HEIGHT

INSPECTION, and if necessary, adjusted

according to Section 7, CRIMP HEIGHT

ADJUSTMENT before using the tool.

Refer to Figure 1, and select wire of the specified size

and insulation diameter. Strip the wire to the

dimension given in Figure 1, taking care not to nick or

cut wire strands. Then proceed as follows:

1. Hold the tool so that the back (wire side) faces

you. Close the tool handles until the ratchet

releases, then allow the handles to open FULLY.

2. Insert the contact (insulation barrel first) into the

front of the appropriate crimping chamber (refer to

the markings on the die).

3. Position the contact so that the mating end is on

the locator side of the tool frame and the open “U” of

the wire barrel and insulation barrel faces the top of

Insulation Anvil

Die

Long Die Retaining

Screw

Die Retaining Pin

(4 Places)

Insulation

Crimper

Die Chamfer

Wire Anvil

Die

Offset

Chamfer

Wire Crimper

Die

Locator Assembly

Nut

Locator

Tool Jaws

Short Die Retaining

Screw

NOTE

408-4007

3of 5

Rev D

Figure 3

the tool frame. Place the contact up into the

crimping chamber so that the locator drops into the

slot in the contact. Refer to Figure 3. Butt the front

end of the wire barrel against the locator.

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 close the tool

handles until the ratchet engages sufficiently to hold

the contact in position. DO NOT deform the

insulation barrel or wire barrel.

5. Insert the stripped wire into contact insulation

barrel and wire barrel until it is butted against the

wire stop as shown in Figure 3.

6. Holding the wire in place, close the tool handles

until the ratchet releases.

7. Allow the tool handles to open FULLY, and

remove the crimped contact.

The crimped contact may stick in the crimping area;

however the contact can be removed by pushing

downward on the top of the locator (see Figure 3).

8. Check the contact crimp height, and if necessary,

adjust the crimp height

DO NOT use defective or damaged products.

5. ADJUSTMENTS

5.1. Contact Support

The contact support is preset prior to shipment, but

minor adjustment may be necessary if the contact is

bending during crimping.

Proceed as follows:

1. Make a sample crimp and determine if the

contact is bending (upward or downward).

2. Loosen the screw that holds the contact support

onto the locator assembly.

3. Place a contact with a wire into the proper

crimping chamber, and close the tool handles until

the ratchet reaches the sixth click or until the

contact support touches the contact.

The ratchet has detents that create audible clicks

as the tool handles are closed.

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, then close the handles until the

ratchet releases.

7. Remove and inspect the contact. 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.

Contact Support

Adjustment

Screw for

Contact Support

Wire

Back of

Tool Frame

(Wire Side)

Locator in

Wire Stop Slot

of Contact

Wire Strip Length

Crimping

Chamber

Wire Inserted

to Wire Stop

CAUTION

NOTE

CAUTION

NOTE

408-4007

4of 5

Rev D

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. 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

market crimp height comparators. Refer to Instruction

Sheet 408-7224 for detailed information on obtaining

and using a crimp height comparator.

Proceed as follows:

1. Refer to Figure 5, and select a maximum size

wire for each crimping chamber.

2. Crimp the contacts according to Section 4.

3. Using a crimp height comparator, measure the

wire barrel crimp height as shown in Figure 4. If the

crimp height conforms to the dimension, the tool

assembly is considered dimensionally correct. If

not, the tool frame must be adjusted. Refer to

Paragraph 5.2, Crimp Height Adjustment.

7. MAINTENANCE AND INSPECTION

7.1. 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.

Figure 5

3. Remove all lubrication and accumulated film from

the dies by immersing the dies in a suitable

commercial degreaser.

7.2. 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.

8. 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 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

9. REVISION SUMMARY

Revisions to this instruction sheet include:

•Updated document to corporate requirements

•New logo

Screwdriver

Lockscrew

RatchetAdjustment

Wheel

CRIMPING

CHAMBER

MARKING

MAXIMUM

WIRE SIZE

(AWG)

DIMENSION A

CRIMP HEIGHT

(mm [in.])

26-28 26 0.69±0.05 [.027±.002]

22-24 22 0.79±0.05 [.031±.002]

Position Point on

Center of Wire Barrel

Opposite Seam A

(See Table)

408-4007

5of 5

Rev D

Tooling Compatible with Die Assembly 90800-2

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)

“C”-Head Assembly 2031450-1

With Shoulder Dies Only

(Instruction Sheet 408-10311)

Closed Head Assembly 2031460-1

With Pin Dies or Shoulder Dies

(Instruction Sheet 408-10312)

Electro-Hydraulic (BT 3500 Battery-Hydraulic)

Hand Tool Kits 2031400-[ ]

(Customer Manual 409-10095)

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