Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO- CRIMPER* III Hand Crimping

Tool Assembly 91338- 1 408--8377

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

22 JUL 09 Rev Awith Die Assembly 91338- 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.

Stationary Jaw

Pivot Pin

PRO--CRIMPER III

Hand Crimping Tool Frame

354940--1 (408--9930)

Back of Tool

(Wire Side)

Stationary Handle

Movable Handle

ocator

Assembly

Contact Support

Die Assembly

Moving Jaw

Ratchet Adjustment

Wheel

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 114 series specification, but may not comply with other feature

parameters of the specification. A variety of tools is offered to satisfy your

performance requirements. For additional information, contact the Tooling

Assistance Center at 1--800--722--1111.

Wire

TE Die Assembly Locator Assembly{Product Family}Size

(AWG)

Insulation Diameter

(Max.) Strip Length

0.64 mm 20 1.85 [.073]

[

]

91338--2 58515--1

Contacts 18 2.13 [.084] 3.81 [.150

]

{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

91338--1 consists of Die Assembly 91338--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 contacts.

All dimensions on this document are in

millimeters [with inches in brackets]. Figures are

not drawn to scale.

Reason for revision will be listed in Section 11,

REVISION SUMMARY.

2. DESCRIPTION

The tool features a tool frame with a stationary jaw

and handle, moving jaw, moving handle, and

adjustable ratchet that ensures full contact crimping.

The tool frame holds a die assembly with two

crimping chambers. See Figure 1.

The die assembly features a wire anvil, insulation

anvil, wire crimper, and insulation crimper.

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.

NOTE

408- 8377

PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1

Rev A2 of 6 Tyco Electronics Corporation

Locator Assembly

Figure 2

Short Die Retaining

Screw

Long Die Retaining

Screw

Short

Die Retaining

Pins (2)

Tool Frame

Nuts

(2) Contact Locator

Chamfered

Edge (Typ)

Wire Crimper

Wire Anvil

Insulation

Anvil

Insulation

Crimper

Chamfered

Edge (Typ)

Markings Face

Outward (Typ) Long

Die Retaining

Pins (2)

Contact

Support

Attached to the outside of the jaw is a contact

support. A nut is used on the lower die retaining

screw to hold the contact support in place.

3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY,

LOCATOR ASSEMBLY, AND CONTACT SUPPORT

1. Open the tool handles, and remove the two die

retaining screws from the tool jaws. See Figure 2.

2. Place the wire anvil and insulation anvil so that

the chamfered sides and marked surfaces face

outward, when mounted in the moving jaw of the

tool frame.

3. Insert two long die retaining pins through the

tool frame and the anvils.

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 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 two short die retaining pins through the

tool frame and into the crimpers.

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 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.

9. Place the locator assembly over the end of the

long die retaining screw. Position the locator

assembly against the side of the tool jaw.

10. Place a nut onto the end of the long screw and

tighten the nut enough to hold the locator assembly

in place, while still allowing the contact locator to

slide up and down.

11. Place the contact support, with the chamfered

side out, over the end of the short screw and long

pins. Secure with a nut.

12. To disassemble, close the tool handles until the

ratchet releases, remove the two nuts, the locator

assembly, the contact support, the two die

retaining screws, and the four die retaining pins.

Slide the anvils and crimpers out of the tool jaws.

408- 8377

PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1

3of 6Rev ATyco Electronics Corporation

4. CONTACT LOCATOR ADJUSTMENT

The contact locator is preset prior to shipment,

but a 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 locator 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 crimp

section and close the tool handles until the ratchet

reaches the sixth click, or until the contact locator

touches the contact.

4. Slightly loosen the nut that holds the locator

assembly onto the tool frame.

5. Move the contact locator as required to

eliminate the 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 locator screw. If the

contact is still being bent during crimping, repeat

the adjustment procedure.

5. CRIMPING PROCEDURE

This tool is provided with a crimp adjustment

feature. Initially, the crimp height should be

verified as specified in Section 6, CRIMP

HEIGHT INSPECTION, and Section 7,

RATCHET (Crimp Height) ADJUSTMENT, before

using the tool to crimp desired contacts.

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 tool.

Refer to Figure 3, and proceed as follows:

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

facing you. Squeeze 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 tool and into the appropriate crimp section.

3. Place the contact into the contact support and

position the contact so that the mating end is on

the locator side of the tool. Make sure that the

open “U” of the wire barrel and insulation barrel

face the stationary jaw.

4. Carefully close the tool, positioning the contact

so that the movable locator enters the contact wire

stop slot between the wire barrel and contact

shoulder. Butt the wire barrel against the locator.

Figure 3

Wire Strip Length

Locator in Contact

Wire Stop Slot Wire Inserted to

Locator Wire Stop

Tool Stationary Jaw

Locator

Wire

Contact

Mating

End

Contact

Support

Adjustment

Screw for

Contact

Locator

Contact

Support

Back of Tool

(Wire Side)

NOTE

408- 8377

PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1

Rev A4 of 6 Tyco Electronics Corporation

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.

5. 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.

6. Insert stripped wire into contact insulation and

wire barrels until it is butted against the wire stop,

as shown in Figure 3.

7. Holding the wire in place, squeeze tool handles

together until ratchet releases. Allow tool handles

to open and remove crimped contact.

The crimped contact may stick in the crimping

area, but can be removed by pushing downward

on the top of the locator (see Figure 3).

8. Check the contact crimp height as described in

Section 6, CRIMP HEIGHT INSPECTION. If

necessary, adjust the crimp height as described in

Section 7, RATCHET ADJUSTMENT.

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.

To measure the crimp height:

1. Refer to Figure 4 and select a wire (maximum

size) for each crimp section listed in the table.

Position Point on

Center of Wire

Barrel Opposite

Seam

“A”

+.05

+[.002]

Modified

Anvil

Wire Size

AWG (Max.)

Crimp Section

Marking

Crimp Height

Dimension “A”

20 20 1.07 [.042]

18 18 1.19 [.047]

Figure 4

2. Crimp the contact(s) according to the

procedures provided in Section 5, CRIMPING

PROCEDURE.

3. Using the crimp height comparator, measure the

wire barrel crimp height as shown in Figure 4. If the

crimp height conforms to the dimensions provided

in Figure 4, then the tool is considered

dimensionally correct. If the crimp height does not

conform to the dimensions provided, the tool must

be adjusted. Refer to Section 7, RATCHET (Crimp

Height) ADJUSTMENT.

For additional information concerning the use of the

crimp height comparator, refer to Instruction Sheet

408--7424.

7. RATCHET (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. Re--assemble the lockscrew.

5. Make a sample crimp and measure the crimp

height. If the dimension is unacceptable, continue

to adjust the ratchet, and again measure a sample

crimp.

Figure 5

Screwdriver

Ratchet Adjustment

Wheel

Lockscrew

(Typ)

CAUTION

NOTE

408- 8377

PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1

5of 6Rev ATyco Electronics Corporation

8. 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 crimping chambers for worn,

flattened, chipped, or broken areas. If damage or

abnormal wear is evident, the tool must be replaced.

See Section 10, REPLACEMENT AND REPAIR.

10. REPLACEMENT AND REPAIR

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 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 CORPORATION

PO BOX 3608

HARRISBURG PA 17105--3608

11.REVISION SUMMARY

Revisions to this instruction sheet include:

SPRO--CRIMPER II Hand Tool became the

PRO--CRIMPER III Hand Tool;

SCrimp--height comparator information was

revised;

STE logo was applied;

SDocument format was updated to current

corporate requirements; and

SThe back page was added.

408- 8377

PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1

Rev A6 of 6 Tyco Electronics Corporation

Dies 91338- 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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