Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

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.

*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.

1of 6

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

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

408-9967

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Rev D

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

408-9967

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Rev D

4. CONTACT SUPPORT ADJUSTMENT

Thecontact supportis preset priorto shipment,but

minor adjustment may be necessary. Refer to

Figure 3.



NOTE

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

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

408-9967

4of 6

Rev D

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

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

408-9967

5of 6

Rev D

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:

408-9967

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Rev D

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