Tyco Electronics PRO- CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand Crimping
Tool Assembly 91304- 1 with 408--4467
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
21 JUL 09 Rev ADie Assembly 91304- 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.
The PRO--CRIMPER III Hand Crimping Tool Assembly 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. 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.
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 (408--9930)
Pivot Pin
Back of Tool
(Wire Side)
Stationary Jaw
Locator Assembly
L
o
c
a
t
o
r
P
r
o
d
u
c
t
Wire
TE Die Assembly Locator
Assembly{
Product
Family}Size
(AWG)
Insulation Diameter
(Max) (mm [in.])
Strip Length
(mm [in.])
9
1
3
0
4
2
5
8
6
6
2
1
Junior Timer Contacts
1
7
2.01
[.079]
4.7+0.41
[.185+.016]
91304--2 58662--1
Micro Timer Contacts
17 1.6
[.063]
4.32+0.41
[.170+.016]
{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
91304--1 consists of Die Assembly 91304--2 and
PRO--CRIMPER III Hand Tool Frame 354940--1. The
tool is used to crimp the contacts onto the wire size
listedinFigure1.
Read these instructions thoroughly before crimping
any contacts.
Revisons will be listed in Section 10, REVISION
SUMMARY.
Dimensions on this sheet are in millimeters [with
inch equivalents provided in brackets]. Figures
are not drawn to scale.
NOTE
i

408- 4467
PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1
Rev A2 of 6 Tyco Electronics Corporation
Figure 2
Nut Locator
Assembly
Tool Frame
Die Retaining Pin
(4 Places)
Short Die
Retaining Screw
Chamfer
Insulation
Anvil Die
Wire Anvil Die
Wire Crimper Die
Chamfer
Insulation
Crimper Die
Long Die
Retaining Screw
Chamfer
Locator
2. DESCRIPTION (Figures 1 and 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 crimping.
The tool frame holds a die assembly with two
crimping chambers. The die assembly features a wire
anvil die, an insulation anvil die, a wire crimper die,
and an insulation crimper die. 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 ASSEMBLY
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 die and insulation anvil die
so that their chamfered edges and their marked
surfaces face outward, when mounted in the
moving jaw of the tool frame.
3. Insert the two die retaining pins through the jaw
and into the dies.
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 die and insulation
crimper die so that their chamfered edges and their
marked surfaces face outward, when mounted in
the stationary jaw of the tool frame.
6. Insert the two die retaining pins through the jaw
and into the dies.
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 anvil and crimper dies align properly.
Continue closing the tool handles until the ratchet
has engaged sufficiently to hold the dies 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 just enough to hold the locator
assembly in place while still allowing the locator to
slide up and down.
11. To disassemble, squeeze the tool handles until
the ratchet releases, open the tool handles,
remove the nut, the locator assembly, two die
retaining screws and four die retaining pins, and
slide the dies out of the tool jaws.

408- 4467
PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1
3of 6Rev ATyco Electronics Corporation
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
crimping chamber 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 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
Before using the tool, the crimping chambers and
tool ratchet should be inspected as specified in
Section 6, CRIMP HEIGHT INSPECTION, and
adjusted as described in Section 7, RATCHET
ADJUSTMENT
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 dies. Refer to Figure 3 and
proceed as follows:
1. Hold tool so that the back (wire side) is facing
you. Squeeze tool handles together until the
ratchet releases then 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 crimping chamber.
Figure 3
Adjustment
Screw for
Contact
Support
Contact
Support
Locator
Back of Tool
(Wire Side)
Wire Contact
(Typ)
Strip Length
Wire Inserted
to Contact Wire
Stop (Hidden)
Locator in
Wire Stop Slot
Note: Not to scale
NOTE
i
NOTE
i
NOTE
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408- 4467
PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1
Rev A4 of 6 Tyco Electronics Corporation
3. Position the contact so that the mating end is on
the locator side of the tool, and so that the open
“U” of the insulation barrel faces the stationary jaw.
Place the contact up into the crimping chamber so
that the locator drops into the wire stop slot in the
contact. Refer to Figure 3. Butt the end of the
contact against the locator.
Make sure that both sides of the insulation barrel
are started evenly into the crimping chamber. Do
NOT attempt to crimp an incorrectly positioned
contact.
4. Hold the contact in place and squeeze the tool
handles together until ratchet engages sufficiently
to hold the contact in position. Do NOT deform the
insulation barrel or wire barrel.
5. Insert stripped wire into contact insulation barrel
until it is butted against the wire stop as shown in
Figure 3.
6. Holding wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open then remove crimped contact.
The crimped contact may stick in the crimping
chamber. It can be easily removed by pushing
downward on the top of the locator. Refer to
Figure 3.
7. Inspect the crimped contact to ensure that the
crimp is centered on the wire barrel and that the
wire is fully inserted. Check the crimp height as
described in Section 6. If necessary, adjust the
crimp height as described in Section 7.
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.
Proceed as follows:
1. Refer to Figure 4 and select a wire for each
crimping chamber listed.
2. Refer to Section 5, CRIMPING PROCEDURE,
and crimp the contacts accordingly.
Position Point
on Center of
Wire Barrel
Opposite Seam
“A”
Modified
Anvil
Wire Size Crim
p
in
g
Chamber Crim
p
Hei
g
ht
W
i
r
e
S
i
z
e
(AWG)
C
r
i
m
p
i
n
g
C
h
a
m
b
e
r
(Marking)
C
r
i
m
p
H
e
i
g
h
t
(Dim. A)
1
7
JUNIOR 1.27+0.051
[.050+.002]
17
MICRO 1.20+0.051
[.047+.002]
Figure 4
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, the tool is
considered dimensionally correct. If not, the tool
must be adjusted. Refer to Section 7, RATCHET
ADJUSTMENT.
7. RATCHET ADJUSTMENT (Figure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the front of the tool.
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
Figure 5
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
CAUTION
!
NOTE
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408- 4467
PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1
5of 6Rev ATyco Electronics Corporation
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 acceptable, the
adjustment setting is correct. If the dimension is
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp.
8. MAINTENANCE AND INSPECTION
8.1. 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.
8.2. Visual Inspection
The die assembly should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimping chambers for
flattened, chipped, worn, or broken areas. If damage
or abnormal wear is evident, the tool or dies must be
replaced. See Section 9, REPLACEMENT.
9. REPLACEMENT
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 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 717--986--7605, or write to:
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS
PO BOX 3608
HARRISBURG PA 17105--3608
10. REVISION SUMMARY
Revisions to this instruction sheet include:
SChanged PRO--CRIMPER II Hand Tool to
PRO--CRIMPER III Hand Tool;
SApplied the TE logo;
SUpdated format to the current corporate
requirements; and
SRevised the crimp--height comparator
information.

408- 4467
PRO- CRIMPER III Hand Crimping Tool Assembly 91304- 1
Rev A6 of 6 Tyco Electronics Corporation
Dies 91304- 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)