TE Connectivity 91366- 1 User manual

Instruction Sheet
408--8661
1of 4
.2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company
All Rights Reserved
*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
i
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]
2
0
1
8
18 1.22 -- 1.40
[.048 -- .055]
20 -- 18
16 1.60 -- 1.69
[.063 -- .067]
1
6
1
4
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
12
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.