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Stationary Jaw Back of Tool (Wire Side) Pivot Pin PRO-CRIMPER III Hand Crimping Tool Frame 354940-1 (408-9930) Stationary Handle Moving Handle Ratchet Adjustment Wheel Moving Jaw Die Assembly Front of Tool (Locator Side) Locator Assembly (Supplied with Die Assembly) TE DIE ASSEMBLY TE LOCATOR ASSEMBLY† CONTACT FAMILY‡ WIRE SIZE (AWG) INSUL DIA STRIP LENGTH 90871-2 58516-1 .093 Commercial Pin and Socket 20-18 3.56 [.140] Max 3.96 to 4.72 † Supplied with die assembly. Also available separately. ‡ Contact the Tooling Assistance Center or Product Information (see below) for specific contact 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. 1 of 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 408-9966 PRO-CRIMPER* III Hand Crimping Tool Assembly 90871-1 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. Figure 1 1. INTRODUCTION PRO-CRIMPER III Hand Crimping Tool Assembly 90871-1 consists of Die Assembly 90871-2 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 cont acts. NOTE i Dimensions on this sheet are in millimeters [with inch equivalents provided in brackets]. Figures and illustrations are for identification only a nd are not drawn to scale. Reasons for reissue are provided in Section 11, REVISION SUMMAR 2. DESCRIPTION (Figure 1 and 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 an vil, a wire crimper, and an insulation crimper. Attached to the outside of the frame is a locator assemb ly, 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 (Figure 2) 1. Open the tool handles and remove the two die retaining screws from the tool jaws. 2. Place the wire anvil and insulation anvil so that the ir chamfered sides and their marked surfaces face outward, when mounted in the moving jaw of the tool frame. 3. Insert the two die retaining pins. 4. Insert the short die retaining screw through the ja w 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 th at 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. 7. Insert the long die retaining screw through the ja w 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 a nvils and crimpers align properly. 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. 9. Place the locator assembly over the end of the lo ng screw, and position the locator assembly against the side of the tool jaw. 10. Place the nut onto the end of the long screw and tigh ten 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 r atchet 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. 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) NOTE i The contact support is preset prior to shipment, but minor adjustment may be necessary. 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 ho lds the contact support onto the locator assembly.
i 408-9966 3 of 6Rev C The ratchet has detents that create audible clicks as the tool handles are closed. 3. Place a contact with wire into the proper nest and clo se the tool handles until the ratchet reaches the sixt# 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 th e bending of the contact. 6. Tighten the nut and close the handles until the r atchet releases. 7. Remove and inspect the contact. 8. Make another sample crimp. If the contact is stra ight, tighten the contact support screw. If the contact is still being bent during crimping, repeat the adjustment procedure. 5. CRIMPING PROCEDURE NOTE i This tool is provided with a crimp adjustment feature. Initially, the crimp height should be verified as specified in Figure 4. Refer to 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 spe cified 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 yo u. Squeeze tool handles together and allow them to open fully. 2. Holding the contact by the mating end, insert the con tact - 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 con tact 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. CAUTION 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. Contact Support Adjustment Screw for Contact Support Locator Back of Tool (Wire Side) Wire Contact (Typ) Locator in Wire Stop Slot Strip Length Wire Inserted to Stop Figure 3
- 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:
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