Instruction Sheet
PRO-CRIMPER III Hand Tool
408-10227
Assembly 2063291-1 with
Die Assembly 2063291-2
16 JUL 08
Rev A
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
Back of Tool
Die Assembly)
(Wire Side)
Front of Tool
Pivot Pin
(Locator Side)
Die Assembly
PRO-CRIMPER III Hand
Tool Frame 354940-1
Moving Jaw
(See Instruction Sheet
408-9930)
Ratchet Adjustment Wheel
The PRO-CRIMPER III Hand 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
Stationary Handle
tools in the appropriate 114 application specification, but may not comply
with other feature parameters of the specification. Tyco Electronics offers
a variety of tools to satisfy your performance requirements. For additional
Moving Handle
information, contact the Tooling Assistance Center at 1-800-722-1111.
WIRE
DIE ASSEMBLY
CONTACTS
PART NUMBER
SIZE (AWG)
INSULATION DIA (mm)
1456574-2, 1456841-2, 1924275-2
18
1.60-2.06
1456574-1, 1456841-1, 1924275-1
20-22
1.50-1.85
2063291 2
2063291-2
STRIP LENGTH (mm)
4 0 4 5
4.0-4.5
Refer to Application Specification 114–13183 or Application and Termination Requirements for these contacts.
Figure 1
1. INTRODUCTION
PRO–CRIMPER III Hand Tool Assembly 2063291–1
consists of Die Assembly 2063291–2 and
PRO–CRIMPER III Hand 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.
Figures and illustrations are for identification only
i
and are not drawn to scale.
2. DESCRIPTION (Figures 1 and 2)
The tool features a tool frame with a stationary jaw
and handle, a moving jaw, a moving handle, and an
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
adjustable ratchet that ensures full contact crimping.
The tool frame holds a die assembly with three
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.
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
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LOC B
408-10227
PRO-CRIMPER III Hand Tool Assembly 2063291-1
Nut
Locator
Tool Frame
Assembly
Insulation
Chamfer
Die Retaining
Crimper
Pins
Wire Crimper
Offset
Wire Anvil
Chamfer
Insulation Anvil
Die Retaining Screws
Figure 2
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
their 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
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.
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.
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.
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9. Place the locator assembly over the end of the
long 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 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, 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
The contact support is preset prior to shipment,
but minor adjustment may be necessary.
i
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.
NOTE
The ratchet has detents that create audible clicks
as the tool handles are closed.
i
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.
Tyco Electronics Corporation
Rev
A
PRO-CRIMPER III Hand Tool Assembly 2063291-1
408-10227
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
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.
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 the open “U” of the wire and insulation barrels
must 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.
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.
CAUTION
are started evenly into the crimping section. Do
!
5. CRIMPING PROCEDURE
NOTE
NOT attempt to crimp an improperly positioned
contact.
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.
This tool is provided with a crimp adjustment
feature. Initially, the crimp height should be
i
Make sure that both sides of the insulation barrel
verified as specified in Figure 4. Refer to Section
5. Insert stripped wire into contact insulation and
wire barrels until it is butted against the wire stop,
as shown in Figure 3.
6, CRIMP HEIGHT INSPECTION, and Section 7,
CRIMP HEIGHT ADJUSTMENT, to verify crimp
height before using the tool to crimp desired
contacts and wire sizes.
6. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped contact.
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:
NOTE
The crimped contact may stick in the crimping
area, but the contact can be easily removed by
i
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, CRIMP HEIGHT ADJUSTMENT.
1. Hold the tool so that the back (wire side) is
facing you. Squeeze tool handles together and
allow them to open fully.
Contact
Support
Locator
Back of Tool
(Wire Side)
Adjustment
Contact
Screw for
(Typ)
Strip Length
Contact
Support
Locator in
Wire
Wire Stop
Slot
Wire Inserted
to Stop
Figure 3
Rev
A
Tyco Electronics Corporation
3 of 5
408-10227
PRO-CRIMPER III Hand Tool Assembly 2063291-1
6. CRIMP HEIGHT INSPECTION
This inspection requires the use of a micrometer with
a modified anvil. Tyco Electronics recommends the
modified micrometer (Crimp Height Comparator
RS–1019–5LP) which may be purchased from:
Shearer Industrial Supply Co.
717–767–7575
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp.
Screwdriver
VALCO
610–691–3205
or
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
Ratchet
Adjustment
Wheel
Position Point on
Center of Wire
Lockscrew (Typ)
Barrel Opposite
Seam
Figure 5
Modified
8. MAINTENANCE
Anvil
A"
WIRE SIZE
(AWG) MAX
CRIMP SECTION (WIRE
SIZE MARKING)
CRIMP HEIGHT
DIM. A" (mm)
18
18
1.05
20
20
0.95
22
22
0.90
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.
Figure 4
9. VISUAL INSPECTION
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,
CRIMP HEIGHT ADJUSTMENT.
7. CRIMP HEIGHT ADJUSTMENT (Figure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
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
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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 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 Tyco Electronics 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 (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
11.REVISION SUMMARY
S Initial release of document
Tyco Electronics Corporation
Rev
A
408-10227
PRO-CRIMPER III Hand Tool Assembly 2063291-1
2063291-2 Die Set can be Used in Tools Show Below
Pro-Crimper Hand Tool 354940-1
SDE PEW-12 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)
Battery Tool (Shouldered Die) 1725837-1, -2
Battery Tool (Pin Die) 1213890-1, -2
(Customer Manual 409-10053)
(Customer Manual 409-10065)
Figure 6
Rev A
Tyco Electronics Corporation
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