Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO-CRIMPER* III Hand

Tool Assembly 1976141-1 408-10120

L C B

of 5

2008 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

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

T LING ASSISTANCE CENTER 1-800-722-1111

PR DUCT INF RMATI N1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at

www.tycoelectronics.com

06 MAR 08 Rev B

with Die Assembly 1976141-2

PROPER SE G IDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

applications. A wide selection of powered application equipment for extended-use, production operations is available.

The PR -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 tools in

the appropriate 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 information, contact the

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

Pivot Pin

Stationary Jaw

Back of Tool (Wire Side)

PR -CRIMPER III Hand Tool

Frame 354940-1

(See Instruction Sheet 408-9930)

Stationary Handle

Moving Handle

Ratchet Adjustment Wheel

Moving Jaw

Die Assembly

Front of Tool (Locator Side)

Locator Assembly

(Supplied with Die Assembly)

DIE ASSEMBLY

LOCATOR ASSY

CONTACT

WIRE

DIE ASSEMBLY

PART N MBER

LOCATOR ASSY

PART N MBER

{

CONTACT

FAMILY

}

SIZE

(mm2[AWG]) INS L DIA.

mm [in.] Max. STRIP LENGTH

mm [in.]

1976141 2

58515 1

M LEX 0.35-0.08 1.80 2.79-3.30

1976141

58515

Mini-Fit Jr. [22-28] [.071] [.110-.130]

{

Supplied with die assembly, also available separately.

}

Contact the Tooling Assistance Center number at the bottom of this page

for specific contact part numbers.

Figure 1

1. INTROD CTION

PRO–CRIMPER III Hand Tool Assembly 1976141–1

consists of Die Assembly 1976141–2 and

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

die assembly consists of crimping dies and a locator

assembly. See Figure 1. Read these instructions

thoroughly before crimping any contacts.

Dimensions on this sheet are in millimeters [with

inch equivalents provided in brackets]. Figures

and illustrations are for reference only, and are

not drawn to scale.

2. DESCRIPTION

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 contact crimping.

The tool frame holds a die assembly with two

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.

NOTE

408-10120

PRO-CRIMPER III Hand Tool Assembly 1976141-1

Rev

f5 Tyc Electr nics C rp rati n

Figure 2

Nut L cat r Assembly T l Frame

Die Retaining Pins

Die Retaining Screws

Chamfer

Insulati n Anvil

Wire Anvil

Offset

Wire Crimper

Chamfer

L cat r

Insulati n Crimper

3. INSTALLATION AND REMOVAL OF DIE SET AND

LOCATOR ASSEMBL

(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.

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)

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 nest

and close the tool handles until the ratchet reaches

the sixth click, or until the contact support touches

the contact.

NOTE

408-10120

PRO-CRIMPER III Hand Tool Ass mbly 1976141-1

of 5Rev

Tyco Elec ronics Corpora ion

Figure 3

Back of Tool

(Wire Side)

Wire

Adjus men

Screw for

Con ac

Suppor

Con ac Suppor Loca or

S rip Leng h

Wire Inser ed

o S op

Loca or in Wire

S op Slo

Con ac

(Typ)

4. Slightly loosen the nut that holds the locator

assembly onto the tool frame.

5. Move the contact support 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 support 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

eature. Initially, the crimp height should be

veri ied as speci ied in Figure 4. Re er to

Section 6, CRIMP HEIGHT INSPECTION, and

Section 7, CRIMP HEIGHT ADJUSTMENT, to

veri y crimp height be ore using the tool to crimp

desired contacts and wire sizes.

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:

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. 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

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.

Make sure that both sides o the insulation barrel

are started evenly into the crimping section. Do

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.

5. Insert stripped wire into contact insulation and

wire barrels until it is butted against the wire stop,

as shown in Figure 3.

6. 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 the contact can be easily removed by

pushing downward on the top o 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.

Damaged product should not be used. I a

damaged contact is evident, it should be cut rom

the wire and replaced with a new one. Do not

reterminate contacts.

NOTE

CAUTION

NOTE

CAUTION

408-10120

PRO-CRIMPER III Hand Tool Assembly 1976141-1

Rev

of 5 Ty o Ele troni s Corporation

Position

Point on

Center of

Wire Barrel

Opposite

seam

Modified Anvil Crimp Height

TERMINAL

PART WIRE SIZE

(mm2[AWG])

COND CTOR CRIMP

(REF) INS LATION CRIMP

(REF) P LL

FORCE

(MIN )

NEST

DESIGNATION

N MBER

(mm2[AWG])

HEIGHT WIDTH HEIGHT WIDTH

(MIN

)

N [lbs] 24-22 28-26

0.35 [22] 0.76-0.86

[.030-.034] 1.44

[.057] 1.72

[.068] 1.61

[.063] 40.0 [9.0] X

39 00 0210

0.20 [24] 0.69-0.79

[.027-.031] 1.44

[.057] 1.72

[.068] 1.61

[.063] 31.1 [7.0] X

0210

0.12 [26] 0.64-0.74

[.025-.029] 1.44

[.057] 1.43

[.056] 1.57

[.062] 22.2 [5.0] X

0.08 [28] 0.61-0.71

[.024-.028] 1.44

[.057] 1.43

[.056] 1.57

[.062] 13.3 [3.0] X

Figure 4

6. CRIMP HEIGHT INSPECTION

The cri p height table provided in Figure 4 is

only a reference. Due to the wide range of wires,

strands, insulation dia eters, etc., actual cri p

height easure ents ay vary. A destructive

pull force test should be perfor ed to check hand

tool cri ps. The pull force value MUST exceed

the ini u pull force specifications listed in

Figure 4.

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:

ShearerIndustrialSupplyCo.

717–767–7575 or VALCO

610–691–3205

Proceed as follows:

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

size) for each crimp section listed.

2. Refer to Section 5, CRIMPING PROCEDURE,

and crimp the contact(s) accordingly.

This tool is qualified to pull force only. To

re-certify, strip a wire 12.7 [.500 in.] long,

and cri p a ter inal to that wire. Make sure no

insulation is cri ped. Pull the ter inal and wire

at a rate no faster than 25 [1.000 in.] per

inute.

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 ADJ STMENT

(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

unacceptable, continue to adjust the ratchet, and

again measure a sample crimp.

NOTE

408-10120

PRO-CRIMPER III Han Tool Assembly 1976141-1

of 5Rev

Tyco Electronics Corporation

Figure 5

Scre driver

Ratchet

Adjustment

Wheel

Lockscre

(Typ)

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 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

Updated logo.

Mouser Electronics

Authorized Distributor

Click to View Pricing, Inventory, Delivery & Lifecycle Information:

TE Connectivity:

1976141-1

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