Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand Crimping
Tool Assembly 91338- 1 408--8377
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
22 JUL 09 Rev Awith Die Assembly 91338- 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.
Stationary Jaw
Pivot Pin
PRO--CRIMPER III
Hand Crimping Tool Frame
354940--1 (408--9930)
Back of Tool
(Wire Side)
Stationary Handle
Movable Handle
L
ocator
Assembly
Contact Support
Die Assembly
Moving Jaw
Ratchet Adjustment
Wheel
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 series specification, but may not comply with other feature
parameters of the specification. A variety of tools is offered to satisfy your
performance requirements. For additional information, contact the Tooling
Assistance Center at 1--800--722--1111.
Wire
TE Die Assembly Locator Assembly{Product Family}Size
(AWG)
Insulation Diameter
(Max.) Strip Length
9
1
3
3
8
2
5
8
5
1
5
1
0.64 mm 20 1.85 [.073]
3
8
1
[
1
5
0
]
91338--2 58515--1
0
.
6
4
m
m
Contacts 18 2.13 [.084] 3.81 [.150
]
{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
91338--1 consists of Die Assembly 91338--2 and
PRO--CRIMPER III Hand Crimping Tool Frame
354940--1. The die assembly consists of crimping
dies and a locator assembly.
Read these instructions thoroughly before crimping
any contacts.
All dimensions on this document are in
millimeters [with inches in brackets]. Figures are
not drawn to scale.
Reason for revision will be listed in Section 11,
REVISION SUMMARY.
2. DESCRIPTION
The tool features a tool frame with a stationary jaw
and handle, moving jaw, moving handle, and
adjustable ratchet that ensures full contact crimping.
The tool frame holds a die assembly with two
crimping chambers. See Figure 1.
The die assembly features a wire anvil, insulation
anvil, wire crimper, and insulation crimper.
Die retaining pins and die retaining screws are used
to position and secure the dies in the tool frame.
Attached to the outside of the frame is a locator
assembly, which contains a locator and contact
retainer. A nut is used on the upper die retaining
screw to hold the locator assembly in place.
NOTE
i

408- 8377
PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1
Rev A2 of 6 Tyco Electronics Corporation
Locator Assembly
Figure 2
Short Die Retaining
Screw
Long Die Retaining
Screw
Short
Die Retaining
Pins (2)
Tool Frame
Nuts
(2) Contact Locator
Chamfered
Edge (Typ)
Wire Crimper
Wire Anvil
Insulation
Anvil
Insulation
Crimper
Chamfered
Edge (Typ)
Markings Face
Outward (Typ) Long
Die Retaining
Pins (2)
Contact
Support
Attached to the outside of the jaw is a contact
support. A nut is used on the lower die retaining
screw to hold the contact support in place.
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY,
LOCATOR ASSEMBLY, AND CONTACT SUPPORT
1. Open the tool handles, and remove the two die
retaining screws from the tool jaws. See Figure 2.
2. Place the wire anvil and insulation anvil so that
the chamfered sides and marked surfaces face
outward, when mounted in the moving jaw of the
tool frame.
3. Insert two long die retaining pins through the
tool frame and the anvils.
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 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 two short die retaining pins through the
tool frame and into the crimpers.
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 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 die retaining screw. Position the locator
assembly against the side of the tool jaw.
10. Place a nut onto the end of the long screw and
tighten the nut enough to hold the locator assembly
in place, while still allowing the contact locator to
slide up and down.
11. Place the contact support, with the chamfered
side out, over the end of the short screw and long
pins. Secure with a nut.
12. To disassemble, close the tool handles until the
ratchet releases, remove the two nuts, the locator
assembly, the contact support, the two die
retaining screws, and the four die retaining pins.
Slide the anvils and crimpers out of the tool jaws.

408- 8377
PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1
3of 6Rev ATyco Electronics Corporation
4. CONTACT LOCATOR ADJUSTMENT
The contact locator is preset prior to shipment,
but a 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 locator 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 crimp
section and close the tool handles until the ratchet
reaches the sixth click, or until the contact locator
touches the contact.
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
5. Move the contact locator 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 locator 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
feature. Initially, the crimp height should be
verified as specified in Section 6, CRIMP
HEIGHT INSPECTION, and Section 7,
RATCHET (Crimp Height) ADJUSTMENT, before
using the tool to crimp desired contacts.
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 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. Place the contact into the contact support and
position the contact so that the mating end is on
the locator side of the tool. Make sure that the
open “U” of the wire barrel and insulation barrel
face the stationary jaw.
4. Carefully close the tool, positioning the contact
so that the movable locator enters the contact wire
stop slot between the wire barrel and contact
shoulder. Butt the wire barrel against the locator.
Figure 3
Wire Strip Length
Locator in Contact
Wire Stop Slot Wire Inserted to
Locator Wire Stop
Tool Stationary Jaw
Locator
Wire
Contact
Mating
End
Contact
Support
Adjustment
Screw for
Contact
Locator
Contact
Support
Back of Tool
(Wire Side)
NOTE
i
NOTE
i
NOTE
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408- 8377
PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1
Rev A4 of 6 Tyco Electronics Corporation
Make sure that both sides of the contact
insulation barrel are started evenly into the
crimping chamber. Do NOT attempt to crimp an
improperly positioned contact.
5. 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.
6. Insert stripped wire into contact insulation and
wire barrels until it is butted against the wire stop,
as shown in Figure 3.
7. 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 can be removed by pushing downward
on the top of the locator (see Figure 3).
8. Check the contact crimp height as described in
Section 6, CRIMP HEIGHT INSPECTION. If
necessary, adjust the crimp height as described in
Section 7, RATCHET ADJUSTMENT.
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.
To measure the crimp height:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed in the table.
Position Point on
Center of Wire
Barrel Opposite
Seam
“A”
+.05
+[.002]
Modified
Anvil
Wire Size
AWG (Max.)
Crimp Section
Marking
Crimp Height
Dimension “A”
20 20 1.07 [.042]
18 18 1.19 [.047]
Figure 4
2. Crimp the contact(s) according to the
procedures provided in Section 5, CRIMPING
PROCEDURE.
3. Using the crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. If the
crimp height conforms to the dimensions provided
in Figure 4, then the tool is considered
dimensionally correct. If the crimp height does not
conform to the dimensions provided, the tool must
be adjusted. Refer to Section 7, RATCHET (Crimp
Height) ADJUSTMENT.
For additional information concerning the use of the
crimp height comparator, refer to Instruction Sheet
408--7424.
7. RATCHET (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.
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. Re--assemble the lockscrew.
5. Make a sample crimp and measure the crimp
height. If the dimension is unacceptable, continue
to adjust the ratchet, and again measure a sample
crimp.
Figure 5
Screwdriver
Ratchet Adjustment
Wheel
Lockscrew
(Typ)
CAUTION
!
NOTE
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408- 8377
PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1
5of 6Rev ATyco Electronics Corporation
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 crimping chambers for worn,
flattened, chipped, or broken areas. If damage or
abnormal wear is evident, the tool must be replaced.
See Section 10, REPLACEMENT AND REPAIR.
10. REPLACEMENT AND REPAIR
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 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 CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
11.REVISION SUMMARY
Revisions to this instruction sheet include:
SPRO--CRIMPER II Hand Tool became the
PRO--CRIMPER III Hand Tool;
SCrimp--height comparator information was
revised;
STE logo was applied;
SDocument format was updated to current
corporate requirements; and
SThe back page was added.

408- 8377
PRO- CRIMPER III Hand Crimping Tool Assembly 91338- 1
Rev A6 of 6 Tyco Electronics Corporation
Dies 91338- 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)