Instruction Sheet
PRO-CRIMPER* III Hand
408-8775
Crimping Tool Assembly 91368-1
with Die Assembly 91368-2
20 APR 09
Rev A
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.
Locator Assembly
Stationary Jaw
(Supplied with
Back of Tool
Die Assembly)
(Wire Side)
Front of Tool
Pivot Pin
(Locator Side)
PRO-CRIMPER III Hand
Crimping Tool Frame
Die Assembly
354940-1 (See Instruction
Sheet 408-9930)
Moving Jaw
Ratchet Adjustment Wheel
Stationary Handle
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
Moving Handle
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.
DIE ASSEMBLY
LOCATOR ASSY
PART NUMBER
PART NUMBER
{
WIRE
CONTACT
FAMILY
}
SIZE (AWG)
INSUL DIA
STRIP LENGTH
24
SL156 (LID)
91368-2
58516-1
22-20
Series
Connectors
2.54-2.84
3.96 +0.38
[[.100-.112]]
[[.156 +.015]]
18
{
}
Supplied with die assembly. Also available separately.
Contact the Tooling Assistance Center (see below) for
specific contact part numbers.
Figure 1
Read these instructions thoroughly before crimping
any contacts.
1. INTRODUCTION
PRO–CRIMPER III Hand Crimping Tool
Assembly 91368–1 consists of Die Assembly
91368–2 and PRO–CRIMPER III Hand Crimping Tool
Frame 354940–1. The die assembly consists of
crimping dies and a locator assembly.
E
2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
NOTE
Dimensions given on this document are in
millimeters [with inch equivalents provided in
i
brackets]. Figures and illustrations are for
identification only and are now drawn to scale.
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
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LOC B
408-8775
PRO-CRIMPER III Hand Crimping Tool Assembly 91368-1
Locator
Nut
Tool Frame
Assembly
Insulation
Die Retaining Pins
Crimper
Chamfer
Wire Crimper
Offset
Wire Anvil
Insulation Anvil
Chamfer
Die Retaining Screws
Figure 2
2. DESCRIPTION (Figures 1 and 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.
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.
3. INSTALLATION AND REMOVAL OF DIE SET 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
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
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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.
Tyco Electronics Corporation
Rev
A
408-8775
PRO-CRIMPER III Hand Crimping Tool Assembly 91368-1
4. CONTACT SUPPORT ADJUSTMENT (Figure 3)
NOTE
contact is still being bent during crimping, repeat
the adjustment procedure.
The contact support is preset prior to shipment,
but minor adjustment may be necessary.
5. CRIMPING PROCEDURE
i
NOTE
1. Make a sample crimp and determine if the
contact is straight, bending upward, or bending
downward.
This tool is provided with a crimp adjustment
feature. Initially, the crimp height should be
i
verified as specified in Figure 4. Refer to
Section 6, CRIMP HEIGHT INSPECTION, and
Section 7, CRIMP HEIGHT ADJUSTMENT, to
2. If adjustment is required, loosen the screw that
holds the contact support onto the locator
assembly.
NOTE
The ratchet has detents that create audible clicks
as the tool handles are closed.
i
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.
verify crimp height before 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.
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
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.
5. Move the contact support as required to
eliminate the bending of the contact.
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.
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
Support
Locator
Back of Tool
(Wire Side)
Adjustment
Screw for
Contact
Contact
(Typ)
Strip
Length
Support
Wire
Locator in Wire
Stop Slot
Wire
Inserted to
Stop
Figure 3
Rev
A
Tyco Electronics Corporation
3 of 5
408-8775
PRO-CRIMPER III Hand Crimping Tool Assembly 91368-1
CAUTION
Make sure that both sides of the insulation barrel
are started evenly into the crimping section. Do
!
NOT attempt to crimp an improperly positioned
Position Point
on Center of
Wire Barrel
contact.
Opposite
Seam
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.
NOTE
WIRE SIZE
(AWG) MAX
CRIMP SECTION
(WIRE SIZE MARKING)
24
24
20
22-20
18
18
The crimped contact may stick in the crimping
0.99 +0.05
[.039 +.002]
1.17 +0.05
[.046 +.002]
7. CRIMP HEIGHT ADJUSTMENT (Figure 5)
Figure 3)
Damaged contacts may not be used. If a
damaged contact is evident, it must be cut from
!
0.94 +0.05
[.037 +.002]
pushing downward on the top of the locator (see
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.
CAUTION
CRIMP HEIGHT
DIM. A"
Figure 4
area, but the contact can be easily removed by
i
A"
Modified Anvil
the wire and replaced with a new one.
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.
6. CRIMP HEIGHT INSPECTION
Screwdriver
This inspection requires the use of a micrometer with
a modified anvil. Tyco Electronics does not
manufacture or market these gages. However, TE
recommends using a modified micrometer (Crimp
Height Comparator RS–1019–5LP).
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
Ratchet
Adjustment
2. Refer to Section 5, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
Wheel
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.
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Tyco Electronics Corporation
Lockscrew (Typ)
Figure 5
Rev
A
408-8775
PRO-CRIMPER III Hand Crimping Tool Assembly 91368-1
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.
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.
Rev A
10. REPLACEMENT
Customer–replaceable parts are shown in Figure 1.
Available separately, PRO–CRIMPER III Hand 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 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
PO BOX 3608
HARRISBURG PA 17105–3608
Tools may also be returned to for evaluation and
repair. For tool repair service, contact a Tyco
Electronics Representative at 1–800–526–5136.
11. REVISION SUMMARY
Since the previous release of this instruction sheet:
S The TE logo has been applied;
S The format has been updated; and
S The PRO–CRIMPER II has been changed to
PRO–CRIMPER III.
Tyco Electronics Corporation
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