Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet

PRO-CRIMPER* III Hand

Crimping ool Assembly 91369-1 408-8776

LOC B

of 5

2009 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.

TOOLI G ASSISTA CE CE TER 1-800-722-1111

PRODUCT I FORMATIO 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 APR 09 Rev A

with Die Assembly 91369-2

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduse ofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

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

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 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.

Locator Assembly

(Supplied with

Die Assembly)

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 (See Instruction

Sheet 408-9930)

Pivot Pin

Back of Tool

(Wire Side)

Stationary Jaw

DIE ASSEMBLY LOCA OR ASSY CON AC WIRE

PAR NUMBER PAR NUMBER

{

FAMILY

}

SIZE (AWG) INSUL DIA S RIP LENG H

91369-2 58516-1 SL156 (LID)

Series

Connectors 16 2.54-2.84

[.110-.112] 3.96 +0.38

[.156 +.015]

{

Supplied with die assembly. Also available separately.

}

Contact the Tooling Assistance Center (see below) for

specific contact part numbers.

Figure 1

1. IN RODUC ION

PRO–CRIMPER III Hand Crimping Tool

Assembly 91369–1 consists of Die Assembly

91369–2 and PRO–CRIMPER III Hand Tool Frame

354940–1. The die assembly consists of crimping

dies and a locator assembly.

Read these instructions thoroughly before crimping

any contacts.

Dimensions given on this document are in

millimeters [with inch equivalents provided in

brackets]. Figures and illustrations are for

identification only and are now drawn to scale.

NO E

408-8776

PRO-CRIMPER III Hand Crimping Tool Assem ly 91369-1

Rev

of 5 Tyco Electro ics Corporatio

Figure 2

Nut

Locator

Assembly Tool Frame

Die Retai i g Pi s

Die Retai i g Screws

Chamfer

I sulatio A vil

Wire A vil

Offset

Wire Crimper

Chamfer I sulatio

Crimper

2. DESCRIPTION

(Figures 1 a d 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 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.

3. INSTALLATION AND REMOVAL OF DIE SET 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 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.

408-8776

PRO-CRIMPER III Hand Crimping Tool Ass mbly 91369-1

of 5Rev

Tyco Elect onics Co po ation

4. CONTACT SUPPORT ADJUSTMENT

(Figu e 3)

The contact support s preset pr or to sh pment,

but m nor 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 aud ble cl cks

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.

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

Th s tool s prov ded wth a cr mp adjustment

feature. Int ally, the cr mp he ght should be

ver f ed as spec f ed n F gure 4. Refer to

Sect on 6, CRIMP HEIGHT INSPECTION, and

Sect on 7, CRIMP HEIGHT ADJUSTMENT, to

ver fy cr mp he ght before us ng the tool to crmp

des red contacts and w re s zes.

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.

Figure 3

Contact

(Typ)

St ip

Length

Wi e

Inse ted to

Stop

Locato in Wi e

Stop Slot

Adjustment

Sc ew fo

Contact

Suppo t

Contact

Suppo t Locato

Back of Tool

(Wi e Side)

Wi e

NOTE

408-8776

PRO-CRIMPER III Hand Crimping Tool Assembly 91369-1

Rev

o 5 Tyco Electronics Corporation

Make s re that both sides of the ins lation 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, b t the contact can be easily removed by

p shing downward on the top of the locator (see

Fig re 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 contacts may not be sed. If a

damaged contact is evident, it m st be c t from

the wire and replaced with a new one.

6. CRIMP HEIGHT INSPECTION

This inspection requires the use of a micrometer with

a modified anvil. Tyco Electronics does not

manuafacture or market these gages, however TE

recommends a modified micrometer (Crimp Height

Comparator RS–1019–5LP).

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.

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 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.

Modi ied Anvil A"

Position Point

on Center o

Wire Barrel

Opposite

Seam

IRE SIZE

(A G) MAX CRIMP SECTION

( IRE SIZE MARKING) CRIMP HEIGHT

DIM. A"

16 16 1.50 +0.05

[.059 +.002]

Figure 4

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.

Figure 5

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew (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.

CAUTION

NOTE

CAUTION

408-8776

PRO-CRIMPER III Hand Crimping Tool Ass mbly 91369-1

of 5Rev

Tyco Electronics Corporation

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 Hand 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 1–717–986–7605, or write to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105–3608

Tools may also be returned to for evaluation and

repair. For tool repair service, contact a Tyco

Electronics Representative at 1–800–526–5136.

11. REVISION SUMMARY

Since the previous release of this instruction sheet,

the TE logo was applied.

This manual suits for next models

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