Tyco Electronics PRO- CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO- CRIMPER* III Hand Crimping

Tool Assembly 91304- 1 with 408--4467

LOC B

1of 6

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

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.tycoelectronics.com

21 JUL 09 Rev ADie Assembly 91304- 2

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.

The PRO--CRIMPER III Hand Crimping Tool Assembly 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 114 series 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 information,

contact the Tooling Assistance Center at 1--800--722--1111.

Front of Tool

(Locator Side)

Die Assembly

Moving Jaw

Ratchet Adjustment

Wheel

Moving

Handle

Stationary

Handle

PRO--CRIMPER III Hand

Crimping Tool Frame

354940--1 (408--9930)

Pivot Pin

Back of Tool

(Wire Side)

Stationary Jaw

Locator Assembly

Wire

TE Die Assembly Locator

Assembly{

Product

Family}Size

(AWG)

Insulation Diameter

(Max) (mm [in.])

Strip Length

(mm [in.])

Junior Timer Contacts

2.01

[.079]

4.7+0.41

[.185+.016]

91304--2 58662--1

Micro Timer Contacts

17 1.6

[.063]

4.32+0.41

[.170+.016]

{Supplied with die assembly. Also available separately. }Contact the Tooling Assistance Center or Product Information

(at the number listed below) for specific contact part numbers.

Figure 1

1. INTRODUCTION

PRO--CRIMPER III Hand Crimping Tool Assembly

91304--1 consists of Die Assembly 91304--2 and

PRO--CRIMPER III Hand Tool Frame 354940--1. The

tool is used to crimp the contacts onto the wire size

listedinFigure1.

Read these instructions thoroughly before crimping

any contacts.

Revisons will be listed in Section 10, REVISION

SUMMARY.

Dimensions on this sheet are in millimeters [with

inch equivalents provided in brackets]. Figures

are not drawn to scale.

NOTE

408- 4467

PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1

Rev A2 of 6 Tyco Electronics Corporation

Figure 2

Nut Locator

Assembly

Tool Frame

Die Retaining Pin

(4 Places)

Short Die

Retaining Screw

Chamfer

Insulation

Anvil Die

Wire Anvil Die

Wire Crimper Die

Chamfer

Insulation

Crimper Die

Long Die

Retaining Screw

Chamfer

Locator

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

adjustable ratchet that ensures full crimping.

The tool frame holds a die assembly with two

crimping chambers. The die assembly features a wire

anvil die, an insulation anvil die, a wire crimper die,

and an insulation crimper die. 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 ASSEMBLY

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 die and insulation anvil die

so that their chamfered edges and their marked

surfaces face outward, when mounted in the

moving jaw of the tool frame.

3. Insert the two die retaining pins through the jaw

and into the dies.

4. Insert the short die retaining screw through the

jaw and through both anvil dies. 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 die and insulation

crimper die so that their chamfered edges and their

marked surfaces face outward, when mounted in

the stationary jaw of the tool frame.

6. Insert the two die retaining pins through the jaw

and into the dies.

7. Insert the long die retaining screw through the

jaw and through both crimper dies. 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 anvil and crimper dies align properly.

Continue closing the tool handles until the ratchet

has engaged sufficiently to hold the dies in place,

then tighten both die retaining screws.

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 just enough to hold the locator

assembly in place while still allowing the locator to

slide up and down.

11. To disassemble, squeeze the tool handles until

the ratchet releases, open the tool handles,

remove the nut, the locator assembly, two die

retaining screws and four die retaining pins, and

slide the dies out of the tool jaws.

408- 4467

PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1

3of 6Rev ATyco Electronics Corporation

4. CONTACT SUPPORT ADJUSTMENT (Figure 3)

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

holds the contact support onto the locator

assembly.

The ratchet has detents that create audible clicks

as the tool handles are closed.

3. Place a contact with wire into the proper

crimping chamber 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 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

Before using the tool, the crimping chambers and

tool ratchet should be inspected as specified in

Section 6, CRIMP HEIGHT INSPECTION, and

adjusted as described in Section 7, RATCHET

ADJUSTMENT

Refer to Figure 1 and select wire of the specified size

and insulation diameter. Strip the wire to the length

indicated, taking care not to nick or cut wire strands.

Select an applicable contact and identify the

appropriate crimping chamber according to the wire

size markings on the dies. Refer to Figure 3 and

proceed as follows:

1. Hold tool so that the back (wire side) is facing

you. Squeeze tool handles together until the

ratchet releases then 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 crimping chamber.

Figure 3

Adjustment

Screw for

Contact

Support

Contact

Support

Locator

Back of Tool

(Wire Side)

Wire Contact

(Typ)

Strip Length

Wire Inserted

to Contact Wire

Stop (Hidden)

Locator in

Wire Stop Slot

Note: Not to scale

NOTE

408- 4467

PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1

Rev A4 of 6 Tyco Electronics Corporation

3. Position the contact so that the mating end is on

the locator side of the tool, and so that the open

“U” of the insulation barrel faces the stationary jaw.

Place the contact up into the crimping chamber so

that the locator drops into the wire stop slot in the

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

contact against the locator.

Make sure that both sides of the insulation barrel

are started evenly into the crimping chamber. Do

NOT attempt to crimp an incorrectly 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 the

insulation barrel or wire barrel.

5. Insert stripped wire into contact insulation barrel

until it is butted against the wire stop as shown in

Figure 3.

6. Holding wire in place, squeeze tool handles

together until ratchet releases. Allow tool handles

to open then remove crimped contact.

The crimped contact may stick in the crimping

chamber. It can be easily removed by pushing

downward on the top of the locator. Refer to

Figure 3.

7. Inspect the crimped contact to ensure that the

crimp is centered on the wire barrel and that the

wire is fully inserted. Check the crimp height as

described in Section 6. If necessary, adjust the

crimp height as described in Section 7.

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 be

found in instruction sheet 408--7424.

Proceed as follows:

1. Refer to Figure 4 and select a wire for each

crimping chamber listed.

2. Refer to Section 5, CRIMPING PROCEDURE,

and crimp the contacts accordingly.

Position Point

on Center of

Wire Barrel

Opposite Seam

“A”

Modified

Anvil

Wire Size Crim

Chamber Crim

Hei

(AWG)

(Marking)

(Dim. A)

JUNIOR 1.27+0.051

[.050+.002]

MICRO 1.20+0.051

[.047+.002]

Figure 4

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, the tool is

considered dimensionally correct. If not, the tool

must be adjusted. Refer to Section 7, RATCHET

ADJUSTMENT.

7. RATCHET ADJUSTMENT (Figure 5)

1. Remove the lockscrew from the ratchet

adjustment wheel.

2. With a screwdriver, adjust the ratchet wheel

from the front of the tool.

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew

Figure 5

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

CAUTION

NOTE

408- 4467

PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1

5of 6Rev ATyco Electronics Corporation

adjustment wheel clockwise to a lower--numbered

setting.

4. Re--assemble the lockscrew.

5. Make a sample crimp and measure the crimp

height. If the dimension is acceptable, the

adjustment setting is correct. If the dimension is

unacceptable, continue to adjust the ratchet, and

again measure a sample crimp.

8. MAINTENANCE AND INSPECTION

8.1. 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.

8.2. Visual Inspection

The die assembly should be inspected on a regular

basis to ensure that they have not become worn or

damaged. Inspect the crimping chambers for

flattened, chipped, worn, or broken areas. If damage

or abnormal wear is evident, the tool or dies must be

replaced. See Section 9, REPLACEMENT.

9. 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 Tyco Electronics representative, or call

1--800--526--5142, or send a facsimile of your

purchase order to 717--986--7605, or write to:

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS

PO BOX 3608

HARRISBURG PA 17105--3608

10. REVISION SUMMARY

Revisions to this instruction sheet include:

SChanged PRO--CRIMPER II Hand Tool to

PRO--CRIMPER III Hand Tool;

SApplied the TE logo;

SUpdated format to the current corporate

requirements; and

SRevised the crimp--height comparator

information.

408- 4467

PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1

Rev A6 of 6 Tyco Electronics Corporation

Dies 91304- 2 May Also Be Used with the Following Tools.

PRO-CRIMPER III Hand Tool 354940- 1

(Instruction Sheet 408- 9930)

SDE PEW-12 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)

Battery Tool (Shouldered Die) 1725837-1, -2

(Customer Manual 409-10053)

Battery Tool (Pin Die) 1213890-1, -2

(Customer Manual 409-10065)

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