Tyco Electronics PEW 12 User manual

Instruction Sheet
PEW 12 Hand Tool
Assembly 2031243-1 with 408-10182
L C B
1 of 4
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
08 JAN 08 Rev B
Die Assembly 2031243-2
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
(mm [in.])
INSUL DIA
{ Contact the Tooling Assistance Center at the bottom of this page for specific terminal part numbers.
FAMILY
{
WIRE
SI E
(mm2)STRIP LENGTH
(mm [in.])
DIE ASSEMBLY
PART NUMBER TERMINAL
2031243-2 .250 Series FAST N*
Receptacle
1-1.4
2-3
1.91-3.30
[.075-.130]
The PEW 12 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 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.
5.1-5.9
[.201-.232]
Stationary Jaw
Back of Tool
(Wire Side)
PEW 12 Hand Tool Frame
9-1478240-0
(See Instruction Sheet 408-8851)
Stationary Handle
Moving Handle
Ratchet Adjustment
Wheel
Moving Jaw
Die Assembly
Front of Tool
(Locator Side)
Figure 1
1. INTRODUCTION
PEW 12 Hand Tool Assembly 2031243–1 consists of
Die Assembly 2031243–2 and PEW 12 Hand Tool
Frame 9–1478240–0. See Figure 1. The die
assembly consists of wire and insulation crimping
dies. Read these instructions thoroughly before
crimping any terminals.
Dimensions on this sheet are in millimeters [with
inch equivalents provided in brackets]. Figures
and illustrations are for identification only and are
not drawn to scale.
Reasons for reissue are provided in Section 10,
REVISION SUMMARY.
NOTE
i

408-10182
PEW 12 Han Tool Assembly 2031243-1
Rev B2 of 4 Tyco Electro ics Corporatio
Figure 2
Chamfer
I sulatio
Crimper
Tool Frame
Die Retai i g
Pi s
Die Retai i g
Screws
Chamfer
I sulatio
A vil
Wire A vil
Wire
Crimper
Locator
Subassembly
Locki g Nut
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.
Die retaining pins and die retaining screws are used
to position and secure the dies in the tool frame.
3. INSTALLATION AND REMOVAL OF
DIE SET
(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 a 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 a 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. To disassemble, close the tool handles until the
ratchet releases, remove the two die retaining
screws and the four die retaining pins, and slide
the anvils and crimpers out of the tool jaws.
4. CRIMPING PROCEDURE
Th s tool s prov ded w th 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 5, CRIMP HEIGHT INSPECTION, and
Sect on 6, CRIMP HEIGHT ADJUSTMENT, to
ver fy cr mp he ght before us ng the tool to cr mp
des red term nals 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 terminal
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.
NOTE
i

408-10182
PEW 12 Hand Tool Asse bly 2031243-1
3 of 4Rev B
Tyco Electronics Corporation
2. Holding the terminal by the mating end, insert
the terminal — insulation barrel first — through the
front of the tool and into the appropriate crimp
section.
3. Position the terminal so that the mating end of
the terminal is on the front side of the tool, and so
that the open “U” of the wire and insulation barrels
face the top of the tool. Place the terminal up into
the nest.
4. Rotate the tool sufficiently to be able to view the
front side of the wire crimper, and position the
terminal so that the front edge of the wire barrel is
even with the front edge of the wire crimper, as
shown in Figure 3.
Make sure that both sides of the insulation barrel
are started evenly into the crimping section. Do
NOT attempt to crimp an improperly positioned
terminal.
5. Hold the terminal in position and squeeze the
tool handles together until ratchet engages
sufficiently to hold the terminal in position. Do NOT
deform insulation barrel or wire barrel.
6. Rotate the tool so that the back (wire side) is
once again facing you.
7. Insert stripped wire into terminal insulation and
wire barrels until the end of the wire is even with
the edge of the wire barrel and wire crimper, as
shown in Figure 3.
8. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped terminal.
The crimped terminal may stick in the crimping
area, but the terminal can be easily removed by
pushing downward on the mating end of the
terminal.
9. Check the terminal’s crimp height as described
in Section 5, CRIMP HEIGHT INSPECTION. If
necessary, adjust the crimp height as described in
Section 6, CRIMP HEIGHT ADJUSTMENT.
5. CRIMP HEIGHT INSPECTION
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 4, CRIMPING PROCEDURE,
and crimp the terminal(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 6,
CRIMP HEIGHT ADJUSTMENT.
Figure 3
Back of Tool
(Wire Side)
Wire
Wire Crimper
Strip Length
Wire Barrel
Terminal (Typ)
Front of Wire Barrel
Even ith Edge of
Wire Crimper
CAUTION
!
NOTE
i

408-10182
PEW 12 Hand Tool Assembly 2031243-1
Rev B4 of 4 Tyco Electronics Corporation
Figure 4
WIRE IZE
mm2(MAX) CRIMP ECTION
(WIRE IZE MARKING)
CRIMP HEIGHT
DIM. (A) AND
TOLERANCE (+)
A"
1.4
3
1-1.4
2-3
1.45 " .05
[.057 " .002]
1.73 " .05
[.068 " .002]
6. CRIMP HEIGHT ADJU TMENT (Fi ure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the front side of the tool.
Figure 5
Screwdriver
Ratchet
Adjustment
Wheel Lockscrew (Typ)
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.
7. 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. VI UAL IN PECTION
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 9, REPLACEMENT.
9. REPLACEMENT
Customer–replaceable parts are shown in Figure 1.
Available separately, 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
10. REVI ION UMMARY
S Updated document to corporate requirements
S Changed PRO–CRIMPER* III artwork to PEW
12 artwork in all instances

Mouser Electronics
Authorized Distributor
Click to View Pricing, Inventory, Delivery & Lifecycle Information:
TE Connectivity:
2031243-1