instruction sheet pro- crimper* iii hand crimping tool assembly 91337- 1 408--8378 loc b 1 of 5 e 2009 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 23 jul 09 rev a with die assembly 91337- 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 volum e applications. a wide selection of powered application equipment for extended--use, production operations is available. 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. 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. locator assembly (supplied with die assembly) front of tool (locator side) die assembly moving jaw ratchet adjustment wheel moving handle stationary handle pivot pin back of tool (wire side) stationary jaw pro--crimper iii hand crimping tool frame 354940--1 (408--9930) t e d i e 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.) strip length 9 1 3 3 7 2 5 8 5 1 5 1 s i z e 1 6 c o n t a c t s 18 2.54 [.100] 3 8 1 [ 1 5 0 ] 91337--2 58515--1 size 16 contacts 16--14 3.18 [.125] 3.81 [.150 ] { supplied with die assembly. also available separately. } contact the tooling assistance center or product information (at the numbers listed below) for specific contact part numbers. figure 1 1. introduction pro--crimper iii hand crimping tool assembly 91337--1 consists of die assembly 91337--2 and pro--crimper iii hand 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. reasons for revision are listed in section 10, 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. note i
408- 8378 pro- crimper iii hand crimping tool assembly 91337- 1 rev a 2 of 5 tyco electronics corporation locator assembly figure 2 short die retaining screw long die retaining screw die retaining pins (4) tool frame nut contact locator chamfered edge (typ) wire crimper wire anvil insulation anvil insulation crimper chamfered edge (typ) markings face outward (typ) 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. 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 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 die retaining pins through the tool frame and into the anvils. 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 two 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, 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 die retaining screw. 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. crimping procedure this tool is provided with a crimp adjustment feature. initially, the crimp height should be verified as specified in section 5, crimp height inspection, and section 6, ratchet (crimp height) adjustment, before using the tool to crimp desired contacts. note i
408- 8378 pro- crimper iii hand crimping tool assembly 91337- 1 3 of 5 rev a tyco electronics corporation 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 appropriate3e 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 front (locator side) is facing you. squeeze tool handles together and allow them to open fully. 2. insert the contact?mating end first?into the appropriate crimping chamber. make sure that the open ?u? of the wire barrel and insulation barrel face the stationary jaw. 3. make sure that the wire stop enters the contact wire stop slot between the wire barrel and contact shoulder. 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. 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 can be removed by pushing downward on the top of the locator (see figure 3). 7. check the contact crimp height as described in section 5, crimp height inspection. if necessary, adjust the crimp height as described in section 6, ratchet (crimp height) adjustment. 5. 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. 2. crimp the contact(s) according to the procedures provided in section 4, 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 6, ratchet (crimp height) adjustment. figure 3 wire strip length locator in contact wire stop slot wire inserted to locator wire stop tool stationary jaw locator wire contact caution ! note i
408- 8378 pro- crimper iii hand crimping tool assembly 91337- 1 rev a 4 of 5 tyco electronics corporation 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? 18 18 1.37 [.054] 14 14 1.55 [.061] figure 4 6. 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. 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. figure 5 screwdriver ratchet adjustment wheel lockscrew (typ) 8. 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 flattened, chipped, worn, or broken areas. if damage or abnormal wear is evident, the tool must be replaced. see section 9, replacement and repair. 9. 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 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 10. revision summary revisions to this instruction sheet include: s pro--crimper ii hand tool change to pro--crimper iii hand tool; s crimp--height comparator information revision; s te logo application; s document format update; and s addition of back page (tools using 91337--2).
408- 8378 pro- crimper iii hand crimping tool assembly 91337- 1 5 of 5 rev a tyco electronics corporation dies 91337- 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)
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