TE Connectivity PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

*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

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

408-8739

PRO-CRIMPER* III Hand Crimping

Tool Assembly 91359-1 with

Die Assembly 91359-2 17 JAN 12 Rev B

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.

† Supplied with Die Assembly; Also Available Separately

‡ Contact PRODUCT INFORMATION at the number at the bottom of this page for specific contact part numbers

Figure 1

1. INTRODUCTION

PRO-CRIMPER III Hand Tool Assembly 91359-1

consists of PRO-CRIMPER III Hand Tool Frame

354940-5 and Die Assembly 91359-2. The tool

assembly is used to crimp the contacts onto the wire

listed in Figure 1. Read these instructions thoroughly

before using the tool assembly.

For additional information on the hand tool frame, refer

to 408-9930.

Reasons for reissue of this instruction sheet are

provided in Section 8, REVISION SUMMARY.

Dimensions in this instruction sheet are in metric

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

Figures are not drawn to scale.

2. DESCRIPTION (See Figure 1)

The tool consists of a tool frame with a stationary jaw,

stationary handle, moving jaw, and moving handle and

an adjustable ratchet that ensures full crimping. The

tool features a lower terminal support for supporting

the contact during crimping, and a ratchet adjustment

wheel for adjusting the crimp height.

Die Assembly

Moving Jaw

Ratchet Adjustment

Wheel

Stationary Jaw

Back of Tool Frame

(Wire Side)

Ratchet (Ref)

PRO-CRIMPER III Hand Tool

Frame 354940-5 (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.

Lower Terminal Support

Locator Assembly

Pivot Pin

DIE ASSEMBLY LOCATOR

ASSEMBLY † PRODUCT FAMILY ‡

WIRE

Size

(AWG)

Maximum Insulation

Diameter (mm [in.])

Strip Length

(mm [in.])

91359-2 58515-1

Electronic Control

Unit (ECU)-11

Generation II

18 2.36 [.093]

5.7 [.22]

(Fluoropolymer) 2.62 [.103]

NOTE

ORIGINAL INSTRUCTIONS

408-8739

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Rev B

Figure 2

The tool frame holds a die assembly that consists of a

wire anvil, insulation anvil, wire crimper, and insulation

crimper. When closed, the dies form two crimping

chambers. Die retaining pins and die retaining screws

are used to position and secure the dies in the tool

frame.

Attached to the outside of the frame is a locator

assembly, which contains a locator and contact retainer.

A nut is used on the upper die retaining screw to hold

the locator assembly in place.

3. INSTALLATION AND REMOVAL OF

DIE ASSEMBLY, LOCATOR ASSEMBLY, AND

LOWER TERMINAL SUPPORT (See 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 in the

moving jaws of the tool frame so that the chamfered

sides and marked surfaces face outward when

mounted.

3. Insert the two long die retaining pins through the

holes in the tool frame.

4. Insert the short die retaining screw through the

jaw and 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 in

the stationary jaw of the tool frame so that the

chamfered sides and marked surfaces face outward

when mounted.

6. Insert the two short die retaining pins through the

holes in the tool frame.

7. Insert the long die retaining screw through the

jaw and 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 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

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. Place the lower terminal support over the end of

the short die retaining screw, and position the lower

terminal support against the side of the tool jaw.

12. Place the nut onto the end of the short die

retaining screw, and tighten.

13. To disassemble, close the tool handles until the

ratchet releases, remove the nuts, the locator

assembly, the lower terminal support, the two die

retaining screws, and the four die retaining pins;

then, slide the anvils and crimpers out of the tool

jaws.

Long Die

Retaining Screw

Wire Anvil

Insulation

Anvil

Jaws

Short Die

Retaining Screw Long Die

Retaining Pins

Short Die

Retaining Pins

Nut

Locator Assembly

Lower

Terminal

Support

Chamfer

Offset

Insulation

Crimper

Wire

Crimper

Chamfer

Locator and

Contact Retainer

408-8739

3of 6

Rev B

4. CRIMPING PROCEDURE

This tool is provided with a contact support and a

crimp adjustment feature

. Initially, the contact

support should be checked as specified in

Paragraph 5.1, and the crimp and crimp height

should be verified as specified in Paragraph 5.2,

Ratchet Adjustment and Paragraph 6.3, Crimp

Height Inspection, and before using the tool.

Refer to Figure 1, and select a contact for the wire size

being used. Strip the wire to the length indicated in

Figure 1, taking care not to nick or cut wire strands.

Identify the appropriate crimping chamber according

to the wire size markings on the die assembly. Refer to

Figure 3, and proceed as follows:

1. Squeeze the 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 appropriate crimping chamber.

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 barrel faces the top of the

tool. Place the contact up into the nest of the die so

that the locator drops into the wire stop slot in the

contact. Refer to Figure 3. Butt the front end of the

wire barrel against the locator. Make sure that the

wire stop enters the contact wire stop slot between

the wire barrel and contact shoulder.

Make sure that both sides of the contact insulation

barrel are started evenly into the crimping chamber.

Do not attempt to crimp an improperly positioned

contact.

4. Hold the contact in place, 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 the stripped wire into the contact insulation

barrel and wire barrel until it butts against the wire

stop as shown in Figure 3.

DO NOT use defective or damaged products.

5. TOOL ADJUSTMENTS

5.1. Contact Support Adjustment

The contact support is preset prior to shipment, but

minor adjustment may be necessary.

Make a sample crimp and determine if the contact is

straight. If the contact is bending upward or downward,

make an adjustment as follows:

1. 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.

2. Place a contact and 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.

3. Slightly loosen the nut that holds the locator

assembly onto the tool frame.

4. Move the contact support as required to eliminate

the bending of the contact.

5. Tighten the nut, and close the handles until the

ratchet releases.

Figure 3

NOTE

CAUTION

NOTE

Strip Length

Contact (Ref)

Lower Terminal

Support

Locator in Contact

Wire Stop Slot

Wire

Dies

Back (Wire Side)

of Tool

Wire

Contact Insulation

Barrel

Nest

408-8739

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Rev B

6. Remove and inspect the contact.

7. 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.

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. MAINTENANCE AND INSPECTION

6.1. 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.

3. Remove all lubrication and accumulated film from

the dies by immersing the dies in a suitable

commercial degreaser.

6.2. 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.

6.3. 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. Refer to

instruction sheet 408-7424 for detailed information on

obtaining and using a crimp height comparator.

Inspect the crimp height as follows:

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

wire for each crimping chamber as listed.

2. Crimp the contact according to Section 3,

CRIMPING PROCEDURE.

3. Using the crimp height comparator, measure the

wire barrel crimp height as shown in Figure 5. If the

crimp height conforms to the dimensions provided,

the tool is considered dimensionally correct. If the

crimp height does not conform to the dimensions

provided, the tool must be adjusted. Refer to

Paragraph 5.2, Ratchet Adjustment.

Figure 5

Screwdriver

Lockscrew

RatchetAdjustment

Wheel

WIRE SIZE

(AWG)

CRIMPING CHAMBER

MARKING

CRIMP HEIGHT

DIMENSION A

±0.05 mm [±.002 in.]

(mm [in.])

18 18 1.37 [.054]

16 16 (Fluoropolymer) 1.50 [.059]

Note: Not to Scale

Point on Center

of Wire Barrel

Opposite Seam

Modified

Anvil

408-8739

5of 6

Rev B

7. REPLACEMENT AND REPAIR

Customer-replaceable parts are shown in Figure 1.

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

8. REVISION SUMMARY

Revisions to this instruction sheet include:

•Changed company name and logo

•Added ORIGINAL INSTRUCTIONS to first page

•Replaced trademark with general term in Figures

1 and 4

•Updated tool compatibility on last page

408-8739

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Rev B

Tooling Compatible with Die Assembly 91359-2

SDE-SA Hand Tool 9-1478240-0

(Instruction Sheet 408-8851)

PRO-CRIMPER III Hand Tool Frame 354940-1

(Instruction Sheet 408-9930)

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)

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