TE Connectivity 91366- 1 User manual

Instruction Sheet

408--8661

1of 4

.2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company

*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.

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

14 JUN 12 Rev AHand Crimping Tool 91366- 1

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.

Figure 1

Crimpers

Anvils

Back Side

of Tool

Ratchet

Crimping Section

Wire Size Markings

Contact

Support

Locator

Crimping

Dies

16--14

20--18

Back of Tool

(Wire Side)

1. INTRODUCTION

Hand Crimping Tool 91366--1 (shown in Figure 1) is

designed to crimp bulk head contacts onto wire sizes

No. 20 through 14 AWG. For wire sizes and contact

part numbers, contact the product information number

at the bottom of the page. Read these instructions

thoroughly before using the tool.

Dimensions are in millimeters [followed by inch

equivalents in brackets]. Figures and illustrations

are for identification only and are not drawn to

scale.

2. DESCRIPTION

The hand tool features two fixed crimping dies

(crimpers) and two movable crimping dies (anvils), a

contact support, a locator, an ejector, and a ratchet.

When closed, the dies form two crimping sections,

each marked on the BACK side of the tool with the

wire size range. See Figure 1.

The contact support prevents the contact from

bending during the crimping procedure.

The locator positions the contact between the

crimping dies and limits the insertion distance of the

stripped wire into the contact. In use, it rests in the

locator slot of the contact.

The ejector pulls the locator down and ejects the

crimped contact when the tool handles are fully

opened.

The ratchet ensures full crimping of the contact. Once

engaged, the ratchet will not release until the handles

have been fully closed.

The crimping jaws bottom before the ratchet

releases. This design feature ensures maximum

electrical and tensile performance of the crimp.

Do NOT re--adjust the ratchet.

3. CRIMPING PROCEDURE

Select wire of specified size and insulation diameter.

Strip the wire to the length indicated in Figure 2. Do

NOT cut or nick the wire strands. Select a contact,

and identify the appropriate crimping section

(according to the wire size markings on the BACK of

the tool). Refer to Figure 3 and proceed as follows:

Figure 2

Insulation

Barrel

Locator

Slot

Wire Barrel

Typical

Bulk Head

Contact

Wire Strip

Length

5.0 [.197]

NOTE: Not to Scale

NOTE

CAUTION

408- 8661

Rev A2 of 4

Figure 3

Back Side

of Tool

Wire Slot

in Locator

Stripped

Wire

Locator Slot

in Contact

Wire Barrel

Locator

Contact Support

Ejector

1. Hold tool so BACK (wire side) faces you.

2. Make sure ratchet is released. Squeeze tool

handles together and allow them to open FULLY.

3. Looking straight into BACK of appropriate

crimping section, insert contact (insulation barrel

first) into FRONT of crimping section. Position the

contact in the dies so that the locator enters locator

slot in the contact. The wire barrel should butt

against the tool locator.

4. Hold contact in locator slot and squeeze tool

handles together until anvil starts entry into

crimper. Do NOT deform insulation barrel or wire

barrel.

5. Insert a properly stripped wire through the wire

slot in locator and into wire barrel of contact until

insulation butts against locator.

6. Holding wire in place, squeeze tool handles until

ratchet releases.

7. Allow tool handles to open fully and remove

crimped contact.

Damaged contacts must be replaced with new

ones. The damaged contact must be cut from the

wire, the wire re--stripped, and a new contact

applied.

4. MAINTENANCE AND INSPECTION

4.1. Daily Maintenance

1. Remove all foreign particles with a clean, soft

brush, or a clean, soft, lint--free cloth. Make sure

the proper retaining pins are in place, and are

secured with the proper retaining rings.

2. Make certain all pivot points and bearing

surfaces are protected with a THIN coat of any

good SAE 20 motor oil. Do NOT oil excessively.

3. When the tool is not in use, keep the handles

closed to prevent objects from becoming lodged

between the crimping dies, and store the tool in a

clean, dry area.

4.2. Periodic Inspection

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the tool and/or be supplied to

supervisory personnel responsible for the tool.

Through recommendations call for at least one

inspection a month, the inspection frequency should

be based on the amount of use, ambient working

conditions, operator training and skill, and established

company standards. These visual inspections should

be performed in the following sequence:

1. Remove all lubrication and accumulated film by

immersing the tool (handles partially closed) in a

suitable commercial degreaser that will not affect

paint or plastic material.

2. Make certain all retaining pins are in place and

secured with retaining rings. If replacements are

necessary, refer to parts listed in Figure 5.

CAUTION

408- 8661

3of 4Rev A

3. Close the tool handles until the ratchet releases,

then allow handles to open freely. If they do not

open quickly and fully, the spring is defective and

must be replaced (see Section 5, REPLACEMENT

AND REPAIR).

4. Inspect the head assembly, with special

emphasis on checking for worn, cracked, or broken

dies. If damage to any part of the head assembly is

evident, return the tool to TE Connectivity for

evaluation and repair (see Section 5,

REPLACEMENT AND REPAIR).

4.3. Crimp Height Inspection

Crimp height inspection is performed using 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.

Proceed as follows:

1. Refer to Figure 4, and select a contact and a

maximum wire size for each crimping section.

2. Refer to Section 3, CRIMPING PROCEDURE,

and crimp the contacts accordingly.

3. Using a crimp height comparator, measure wire

barrel crimp height as shown in Figure 4. If the

crimp height conforms to that shown in Figure 4,

the tool is considered dimensionally correct. If not,

return the tool for evaluation and repair (see

Section 5, REPLACEMENT AND REPAIR).

4.4. Ratchet Inspection

Obtain a 0.025 mm [.001 in.] shim that is suitable for

checking the clearance between the bottoming

surfaces of the crimping dies.

Proceed as follows:

1. Select a contact, maximum size wire, and the

designated crimping section for the wire being

used (see Figure 4).

2. Position the contact and wire between the

crimping dies, according to Section 3, CRIMPING

PROCEDURE (Steps 1 through 5). Holding the

wire in place, squeeze the tool handles together

until the ratchet releases. Hold the tool handles in

this position, maintaining just enough pressure to

keep the dies closed.

Position Point on

Center of Wire

Barrel Opposite

Seam

Modified

Anvil

Crimp

Height

WIRE SIZE

AWG (Max)

CRIMP HEIGHT

DIMENSION

HAND TOOL

CRIMPING

SECTION

20 1.22 -- 1.35

[.048 -- .053]

18 1.22 -- 1.40

[.048 -- .055]

20 -- 18

16 1.60 -- 1.69

[.063 -- .067]

14 1.60 -- 1.78

[.063 -- .070]

16 -- 14

Figure 4

3. Check the clearance between the bottoming

surfaces of the crimping dies. If the clearance is

0.025 mm [.001 in.] or less, the ratchet is

satisfactory. If clearance exceeds 0.025 mm

[.001 in.], the ratchet is out of adjustment and must

be repaired (see Section 5, REPLACEMENT AND

REPAIR).

If the tool conforms to these inspection procedures,

lubricate it with a THIN coat of any good SAE 20

motor oil and return it to service.

5. REPLACEMENT AND REPAIR

Replacement parts are listed in Figure 5. Parts other

than those listed in Figure 5 should be replaced by TE

to ensure quality and reliability of the tool. Order

replacement parts through your TE 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

For tool repair service, please contact a TE

Representative at 1--800--526--5136.

408- 8661

Rev A4 of 4

Figure 5

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QUANTITY

1 21045--3 RING, Retaining 4

2 21045--9 RING, Retaining 2

63.5

[2.50]

(Closed)

19.05

[.750]

301.75

[11.88]

WEIGHT: 567g[1lb.4oz.]

6. REVISION SUMMARY

Since the previous version of this document, the

following changes were made:

:Removed incorrect ratchet trademark

references.

:Updated crimp height comparator information.

:Updated document to corporate requirements.

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