Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO-CRIMPER* III Hand
Tool Assembly 1976141-1 408-10120
L C B
1 of 5
E 2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. ther products, logos, and company names used are the property of their respective owners.
T LING ASSISTANCE CENTER 1-800-722-1111
PR DUCT INF RMATI N1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
06 MAR 08 Rev B
with Die Assembly 1976141-2
PROPER SE G IDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
The PR -CRIMPER III Hand 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 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.
Pivot Pin
Stationary Jaw
Back of Tool (Wire Side)
PR -CRIMPER III Hand Tool
Frame 354940-1
(See Instruction Sheet 408-9930)
Stationary Handle
Moving Handle
Ratchet Adjustment Wheel
Moving Jaw
Die Assembly
Front of Tool (Locator Side)
Locator Assembly
(Supplied with Die Assembly)
DIE ASSEMBLY
LOCATOR ASSY
CONTACT
WIRE
DIE ASSEMBLY
PART N MBER
LOCATOR ASSY
PART N MBER {
CONTACT
FAMILY }
SIZE
(mm2[AWG]) INS L DIA.
mm [in.] Max. STRIP LENGTH mm [in.]
1976141 2
58515 1
M LEX 0.35-0.08 1.80 2.79-3.30
1976141
-
2
58515
-
1
Mini-Fit Jr. [22-28] [.071] [.110-.130]
{ Supplied with die assembly, also available separately. } Contact the Tooling Assistance Center number at the bottom of this page
for specific contact part numbers.
Figure 1
1. INTROD CTION
PRO–CRIMPER III Hand Tool Assembly 1976141–1
consists of Die Assembly 1976141–2 and
PRO–CRIMPER III Hand Tool Frame 354940–1. The
die assembly consists of crimping dies and a locator
assembly. See Figure 1. Read these instructions
thoroughly before crimping any contacts.
Dimensions on this sheet are in millimeters [with
inch equivalents provided in brackets]. Figures
and illustrations are for reference only, and are
not drawn to scale.
2. DESCRIPTION
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.
NOTE
i

408-10120
PRO-CRIMPER III Hand Tool Assembly 1976141-1
Rev B2 f5 Tyc Electr nics C rp rati n
Figure 2
Nut L cat r Assembly T l Frame
Die Retaining Pins
Die Retaining Screws
Chamfer
Insulati n Anvil
Wire Anvil
Offset
Wire Crimper
Chamfer
L cat r
Insulati n Crimper
3. INSTALLATION AND REMOVAL OF DIE SET AND
LOCATOR ASSEMBL
(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.
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 nest
and close the tool handles until the ratchet reaches
the sixth click, or until the contact support touches
the contact.
NOTE
i
NOTE
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408-10120
PRO-CRIMPER III Hand Tool Ass mbly 1976141-1
3 of 5Rev B
Tyco Elec ronics Corpora ion
Figure 3
Back of Tool
(Wire Side)
Wire
Adjus men
Screw for
Con ac
Suppor
Con ac Suppor Loca or
S rip Leng h
Wire Inser ed
o S op
Loca or in Wire
S op Slo
Con ac
(Typ)
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
This tool is provided with a crimp adjustment
eature. Initially, the crimp height should be
veri ied as speci ied in Figure 4. Re er to
Section 6, CRIMP HEIGHT INSPECTION, and
Section 7, CRIMP HEIGHT ADJUSTMENT, to
veri y crimp height be ore using the tool to crimp
desired contacts and wire sizes.
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.
Make sure that both sides o the insulation 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, but the contact can be easily removed by
pushing downward on the top o the locator (see
Figure 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 product should not be used. I a
damaged contact is evident, it should be cut rom
the wire and replaced with a new one. Do not
reterminate contacts.
NOTE
i
CAUTION
!
NOTE
i
CAUTION
!

408-10120
PRO-CRIMPER III Hand Tool Assembly 1976141-1
Rev B4 of 5 Ty o Ele troni s Corporation
Position
Point on
Center of
Wire Barrel
Opposite
seam
Modified Anvil Crimp Height
TERMINAL
PART WIRE SIZE
(mm2[AWG])
COND CTOR CRIMP
(REF) INS LATION CRIMP (REF) P LL
FORCE
(MIN )
NEST
DESIGNATION
N MBER
(mm2[AWG])
HEIGHT WIDTH HEIGHT WIDTH
(MIN
.
)
N [lbs] 24-22 28-26
0.35 [22] 0.76-0.86
[.030-.034] 1.44 [.057] 1.72 [.068] 1.61 [.063] 40.0 [9.0] X
39 00 0210
0.20 [24] 0.69-0.79
[.027-.031] 1.44 [.057] 1.72 [.068] 1.61 [.063] 31.1 [7.0] X
39
-
00
-
0210
0.12 [26] 0.64-0.74
[.025-.029] 1.44 [.057] 1.43 [.056] 1.57 [.062] 22.2 [5.0] X
0.08 [28] 0.61-0.71
[.024-.028] 1.44 [.057] 1.43 [.056] 1.57 [.062] 13.3 [3.0] X
Figure 4
6. CRIMP HEIGHT INSPECTION
The cri p height table provided in Figure 4 is
only a reference. Due to the wide range of wires,
strands, insulation dia eters, etc., actual cri p
height easure ents ay vary. A destructive
pull force test should be perfor ed to check hand
tool cri ps. The pull force value MUST exceed
the ini u pull force specifications listed in
Figure 4.
This inspection requires the use of a micrometer with
a modified anvil. Tyco Electronics recommends the
modified micrometer (Crimp Height Comparator
RS–1019–5LP) which may be purchased from:
ShearerIndustrialSupplyCo.
717–767–7575 or VALCO
610–691–3205
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.
This tool is qualified to pull force only. To
re-certify, strip a wire 12.7 [.500 in.] long,
and cri p a ter inal to that wire. Make sure no
insulation is cri ped. Pull the ter inal and wire
at a rate no faster than 25 [1.000 in.] per
inute.
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 ADJ STMENT (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. 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.
NOTE
i
NOTE
i

408-10120
PRO-CRIMPER III Han Tool Assembly 1976141-1
5 of 5Rev B
Tyco Electronics Corporation
Figure 5
Scre driver
Ratchet
Adjustment
Wheel
Lockscre
(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.
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 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
P.O. BOX 3608
HARRISBURG, PA 17105–3608
11.REVISION SUMMARY
S Updated logo.

Mouser Electronics
Authorized Distributor
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TE Connectivity:
1976141-1