Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 90800-1 with 408-4007 Die Assembly 90800-2 19 APR 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. Stationary Jaw Locator Assembly (Supplied with Die Assembly) Pivot Pin Die Assembly Back of Tool Frame (Wire Side) Moving Jaw Ratchet Die Retaining Screw (2 Places) PRO-CRIMPER III Hand Tool Frame 354940-1 (408-9930) Ratchet Adjustment Wheel The PRO-CRIMPER III Hand Crimping Tool is a Commercial grade tool and is Stationary Handle 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 Moving Handle 1-800-722-1111. WIRE LOCATOR INSULATION DIE ASSEMBLY PRODUCT FAMILY SIZE RANGE STRIP LENGTH ASSEMBLY DIAMETER (AWG) (mm in. ) (mm in. ) AMPLIMITE* HD 0.76-1.02 3.56-3.96 90800-2 58516-1 28-22 Crimp-Snap Contacts .030-.040 .140-.156 Figure 1 1. INTRODUCTION Reasons for reissue of this instruction sheet are provided in Section 9, REVISION SUMMARY. PRO-CRIMPER III Hand Tool Assembly 90800-1 consists of PRO-CRIMPER III Hand Tool Frame 2. DESCRIPTION (See Figure 1) 354940-1 and Die Assembly 90800-2. The tool The tool consist of a stationary jaw and handle, a assembly is used to crimp the contacts given in Figure 1, moving jaw and handle, and an adjustable ratchet that ensures full crimping. The tool features a ratchet Read these instructions thoroughly before using the adjustment wheel for adjusting the crimp height. tool assembly. A locator assembly is attached to the tool frame and Dimensions in this instruction sheet are in metric NOTE consists of a locator, spring retainer, and contact units with U.S. customary units in brackets . support. The contact support prevents the contact from Figures are not drawn to scale. bending during crimping. A nut used on the long die i retaining screw holds the locator assembly in place. For additional information on the hand tool frame, refer The die assembly consists of two anvil dies (wire and to 408-9930. insulation) and two crimper dies (wire and insulation). 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 5 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. ORIGINAL INSTRUCTIONS408-4007 Locator Assembly Nut Tool Jaws Locator Wire Crimper Die Die Retaining Pin (4 Places) Chamfer Long Die Retaining Screw Offset Insulation Insulation Anvil Short Die Retaining Crimper Wire Anvil Die Screw Die Chamfer Die Figure 2 When closed, the dies form two crimping chambers. 9. Place the locator assembly over the end of the Each die is held in the tool frame by a retaining screw long die retaining screw, and position the locator and two retaining pins. assembly against the side of the tool jaw. 10. Place the nut onto the end of the long die 3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY retaining screw, and tighten the nut enough to hold AND LOCATOR ASSEMBLY the locator assembly in place, while still allowing the locator to slide up and down. 1. Close the tool handles until the ratchet releases, then allow the handles to open fully. 11. To disassemble, close the tool handles until the ratchet releases. Remove the nut, locator assembly, 2. Remove the two die retaining screws from the the two die retaining screws, and four die retaining tool jaws. pins, then, slide the dies out of the tool jaws. 3. Slide the wire anvil and insulation anvil dies onto the moving jaw so that the chamfers and marked 4. CRIMPING PROCEDURE surfaces face outward as shown in Figure 2, then The tool frame is provided with a crimp adjustment insert the two die retaining pins through the holes in NOTE feature. Initially, the crimp height should be verified the moving jaw and into the holes in the dies. according to Section 6, CRIMP HEIGHT i 4. Thread, but do not tighten, the short die retaining INSPECTION, and if necessary, adjusted screws through the holes of the moving jaw and into according to Section 7, CRIMP HEIGHT the holes in both anvil dies. ADJUSTMENT before using the tool. 5. Slide the wire crimper and insulation crimper dies Refer to Figure 1, and select wire of the specified size onto the stationary jaw so that the chamfers and and insulation diameter. Strip the wire to the marked surfaces face outward as shown in Figure 2, dimension given in Figure 1, taking care not to nick or then insert the two die retaining pins through the holes cut wire strands. Then proceed as follows: in the stationary jaw and into the holes in the dies. 1. Hold the tool so that the back (wire side) faces 6. Thread, but do not tighten, the long die retaining you. Close the tool handles until the ratchet screws through the holes of the moving jaw and into releases, then allow the handles to open FULLY. the holes in both crimper dies. 2. Insert the contact (insulation barrel first) into the 7. Carefully close the tool handles, making sure that front of the appropriate crimping chamber (refer to the dies align properly. Continue closing the the markings on the die). handles until the ratchet has engaged sufficiently to 3. Position the contact so that the mating end is on hold the dies in place. the locator side of the tool frame and the open U of 8. Tighten the die retaining screws using the the wire barrel and insulation barrel faces the top of appropriate screwdriver. Rev D 2 of 5