PRO- CRIMPER* III Hand Crmpng Instructon Sheet Tool Assembly 91338-1 408-8377 wth De Assembly 91338-2 22 JUL 09 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended -use, producton operatons s avalable. Support De Assembly Locator Assembly Movng Jaw Ratchet Adjustment Wheel The PRO -CRIMPER III Hand Crmpng Tool s a Commercal grade tool and s desgned prmarly for feld nstallaton, repar, mantenance work, or prototypng n ndustral, commercal, or nsttutonal applcatons. Product crmped wth ths tool wll meet the crmp heght requrement for hand tools n the approprate 114 seres specfcaton, but may not comply wth other feature parameters of the specfcaton. A varety of tools s offered to satsfy your performance requrements. For addtonal nformaton, contact the Toolng Assstance Center at 1-800 -722-1111. Statonary Jaw Pvot Pn PRO -CRIMPER III Hand Crmpng Tool Frame 354940-1 (408-9930) Back of Tool (Wre Sde) Statonary Handle Movable Handle TE De Assembly Locator Assembly{ Product Famly} Sze (AWG) 91338-2 58515-1 Wre Insulaton Dameter (Max.) 0.64 mm 20 1.85 [.073] s 18 2.13 [.084] Strp Length 3.81 [.150] { Suppled wth de assembly. Also avalable separately. } the Toolng Assstance Center or Product Informaton (at the number lsted below) for specfc contact part numbers. 1. INTRODUCTION PRO--CRIMPER III Hand Crmpng Tool Assembly 91338--1 conssts of De Assembly 91338--2 and PRO--CRIMPER III Hand Crmpng Tool Frame 354940--1. The de assembly conssts of crmpng des and a locator assembly. Read these nstructons thoroughly before crmpng any contacts. All dmensons on ths document are n mllmeters [wth nches n brackets]. Fgures are not drawn to scale. Reason for revson wll be lsted n Secton 11, REVISION SUMMARY. Fgure 1 2. DESCRIPTION The tool features a tool frame wth a statonary jaw and handle, movng jaw, movng handle, and adjustable ratchet that ensures full contact crmpng. The tool frame holds a de assembly wth two crmpng chambers. See Fgure 1. The de assembly features a wre anvl, nsulaton anvl, wre crmper, and nsulaton crmper. De retanng pns and de retanng screws are used to poston and secure the des n the tool frame. Attached to the outsde of the frame s a locator assembly, whch contans a locator and contact retaner. A nut s used on the upper de retanng screw to hold the locator assembly n place. E2009 Tyco Electroncs Corporaton, Harrsburg, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Internatonal Rghts Reserved PRODUCT INFORMATION 1-800 -522-6752 TE logo and Tyco Electroncs are trademarks. *Trademark. Other products, logos, and company names used are the property of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.tycoelectroncs.com 1 of 6 LOC B
Nuts Locator Assembly (2) Locator Tool Frame Chamfered Edge (Typ) Short De Retanng Pns (2) Wre Crmper Support Long De Retanng Screw Wre Anvl Insulaton Crmper Markngs Face Outward (Typ) Chamfered Edge (Typ) Insulaton Anvl Short De Retanng Screw Long De Retanng Pns (2) Attached to the outsde of the jaw s a contact support. A nut s used on the lower de retanng screw to hold the contact support n place. 3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY, LOCATOR ASSEMBLY, AND CONTACT SUPPORT 1. Open the tool handles, and remove the two de retanng screws from the tool jaws. See Fgure 2. 2. Place the wre anvl and nsulaton anvl so that the chamfered sdes and marked surfaces face outward, when mounted n the movng jaw of the tool frame. 3. Insert two long de retanng pns through the tool frame and the anvls. 4. Insert the short de retanng screw through the jaw and through both anvl des. Tghten the screw just enough to hold the des n place. Do not tghten the screw completely at ths tme. 5. Place the wre crmper and nsulaton crmper so that ther chamfered sdes and ther marked surfaces face outward, when mounted n the statonary jaw of the tool frame. 6. Insert two short de retanng pns through the tool frame and nto the crmpers. Fgure 2 7. Insert the long de retanng screw through the jaw and through both crmper des. Tghten the screw just enough to hold the des n place. Do not tghten the screw completely at ths tme. 8. Carefully close the tool handles, makng sure that the anvls and crmpers algn properly. Contnue closng the tool handles untl the ratchet n the tool frame has engaged suffcently to hold the anvls and crmpers n place, then tghten both de retanng screws. 9. Place the locator assembly over the end of the long de retanng screw. Poston the locator assembly aganst the sde of the tool jaw. 10. Place a nut onto the end of the long screw and tghten the nut enough to hold the locator assembly n place, whle stll allowng the contact locator to slde up and down. 11. Place the contact support, wth the chamfered sde out, over the end of the short screw and long pns. Secure wth a nut. 12. To dsassemble, close the tool handles untl the ratchet releases, remove the two nuts, the locator assembly, the contact support, the two de retanng screws, and the four de retanng pns. Slde the anvls and crmpers out of the tool jaws. 2 of 6 Tyco Electroncs Corporaton
4. CONTACT LOCATOR ADJUSTMENT The contact locator s preset pror to shpment, but a mnor adjustment may be necessary. 1. Make a sample crmp and determne f the contact s straght, bendng upward, or bendng downward. 2. If adjustment s requred, loosen the screw that holds the contact locator onto the locator assembly. The ratchet has detents that create audble clcks as the tool handles are closed. 3. Place a contact wth wre nto the proper crmp secton and close the tool handles untl the ratchet reaches the sxth clck, or untl the contact locator touches the contact. 4. Slghtly loosen the nut that holds the locator assembly onto the tool frame. 5. Move the contact locator as requred to elmnate the bendng of the contact. 6. Tghten the nut and close the handles untl the ratchet releases. 7. Remove and nspect the contact. 8. Make another sample crmp. If the contact s straght, tghten the contact locator screw. If the contact s stll beng bent durng crmpng, repeat the adjustment procedure. 5. CRIMPING PROCEDURE Ths tool s provded wth a crmp adjustment feature. Intally, the crmp heght should be verfed as specfed n Secton 6, CRIMP HEIGHT INSPECTION, and Secton 7, RATCHET (Crmp Heght) ADJUSTMENT, before usng the tool to crmp desred contacts. Refer to Fgure 1, and select wre of the specfed sze and nsulaton dameter. Strp the wre to the length ndcated, takng care not to nck or cut wre strands. Select an applcable contact and dentfy the approprate crmpng chamber accordng to the wre sze markngs on the tool. Refer to Fgure 3, and proceed as follows: 1. Hold the tool so that the back (wre sde) s facng you. Squeeze tool handles together and allow them to open fully. 2. Holdng the contact by the matng end, nsert the contact -- nsulaton barrel frst -- through the front of the tool and nto the approprate crmp secton. 3. Place the contact nto the contact support and poston the contact so that the matng end s on the locator sde of the tool. Make sure that the open U of the wre barrel and nsulaton barrel face the statonary jaw. 4. Carefully close the tool, postonng the contact so that the movable locator enters the contact wre stop slot between the wre barrel and contact shoulder. Butt the wre barrel aganst the locator. Adjustment Screw for Locator Locator Back of Tool (Wre Sde) Wre Matng End Tool Statonary Jaw Wre Strp Length Support Support Locator n Wre Stop Slot Wre Inserted to Locator Wre Stop Fgure 3 Tyco Electroncs Corporaton 3 of 6
CAUTION! Make sure that both sdes of the contact nsulaton barrel are started evenly nto the crmpng chamber. Do NOT attempt to crmp an mproperly postoned contact. 5. Hold the contact n poston, and squeeze the tool handles together untl ratchet engages suffcently to hold the contact n poston. Do NOT deform nsulaton barrel or wre barrel. 6. Insert strpped wre nto contact nsulaton and wre barrels untl t s butted aganst the wre stop, as shown n Fgure 3. 7. Holdng the wre n place, squeeze tool handles together untl ratchet releases. Allow tool handles to open and remove crmped contact. The crmped contact may stck n the crmpng area, but can be removed by pushng downward on the top of the locator (see Fgure 3). 8. Check the contact crmp heght as descrbed n Secton 6, CRIMP HEIGHT INSPECTION. If necessary, adjust the crmp heght as descrbed n Secton 7, RATCHET ADJUSTMENT. 6. CRIMP HEIGHT INSPECTION Crmp heght nspecton s performed through the use of a mcrometer wth a modfed anvl, commonly referred to as a crmp--heght comparator. Tyco Electroncs does not manufacture or market crmp--heght comparators. Detaled nformaton on obtanng and usng crmp--heght comparators can be found n nstructon sheet 408--7424. To measure the crmp heght: 1. Refer to Fgure 4 and select a wre (maxmum sze) for each crmp secton lsted n the table. 3. Usng the crmp heght comparator, measure the wre barrel crmp heght as shown n Fgure 4. If the crmp heght conforms to the dmensons provded n Fgure 4, then the tool s consdered dmensonally correct. If the crmp heght does not conform to the dmensons provded, the tool must be adjusted. Refer to Secton 7, RATCHET (Crmp Heght) ADJUSTMENT. For addtonal nformaton concernng the use of the crmp heght comparator, refer to Instructon Sheet 408--7424. 7. RATCHET (Crmp Heght) ADJUSTMENT (Fgure 5) 1. Remove the lockscrew from the ratchet adjustment wheel. 2. Wth a screwdrver, adjust the ratchet wheel from the locator sde of the tool. 3. Observe the ratchet adjustment wheel. If a tghter crmp s requred, rotate the adjustment wheel counterclockwse to a hgher--numbered settng. If a looser crmp s requred, rotate the adjustment wheel clockwse to a lower--numbered settng. 4. Re--assemble the lockscrew. 5. Make a sample crmp and measure the crmp heght. If the dmenson s unacceptable, contnue to adjust the ratchet, and agan measure a sample crmp. Screwdrver Poston Pont on Center of Wre Barrel Opposte Seam Modfed Anvl A +.05 +[.002] Ratchet Adjustment Wheel Lockscrew (Typ) Wre Sze AWG (Max.) Crmp Secton Markng Crmp Heght Dmenson A 20 20 1.07 [.042] 18 18 1.19 [.047] Fgure 4 2. Crmp the contact(s) accordng to the procedures provded n Secton 5, CRIMPING PROCEDURE. Fgure 5 4 of 6 Tyco Electroncs Corporaton
8. MAINTENANCE Ensure that the tool and des are clean by wpng them wth a clean, soft cloth. Remove any debrs wth a clean, soft brush. Do not use objects that could damage the tool. When not n use, keep handles closed to prevent objects from becomng lodged n the crmpng des, and store n a clean, dry area. 9. VISUAL INSPECTION The crmpng des should be nspected on a regular bass to ensure that they have not become worn or damaged. Inspect the crmpng chambers for worn, flattened, chpped, or broken areas. If damage or abnormal wear s evdent, the tool must be replaced. See Secton 10, REPLACEMENT AND REPAIR. 10. REPLACEMENT AND REPAIR Customer--replaceable parts are shown n Fgure 1. Avalable separately, PRO--CRIMPER III Hand Crmpng Tool Repar Kt 679221--1 ncludes a replacement nut and a varety of pns, rngs, screws, and sprngs. If the des are damaged or worn excessvely, they must be replaced. Order repar kt and replaceable parts through your Tyco Electroncs representatve, or call 1--800--526--5142, or send a facsmle of your purchase order to 717--986--7605, or wrte to: CUSTOMER SERVICE (38--35) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105--3608 11.REVISION SUMMARY Revsons to ths nstructon sheet nclude: S PRO--CRIMPER II Hand Tool became the PRO--CRIMPER III Hand Tool; S Crmp--heght comparator nformaton was revsed; S TE logo was appled; S Document format was updated to current corporate requrements; and S The back page was added. Tyco Electroncs Corporaton 5 of 6
Des 91338-2 May Also Be Used wth the Followng Tools. PRO-CRIMPER III Hand Tool 354940-1 (Instructon Sheet 408-9930) SDE PEW- 12 Hand Tool 9-1478240- 0 (Instructon Sheet 408-8851) SDE Bench Termnator 1490076-2 (Customer Manual 409-10052) 626 Adapter 679304-1 (Instructon Sheet 408-4070) Battery Tool (Shouldered De) 1725837-1, - 2 (Customer Manual 409-10053) Battery Tool (Pn De) 1213890-1, - 2 (Customer Manual 409-10065) 6 of 6 Tyco Electroncs Corporaton