TE Connectivity PRO-CRIMPER III Manual de usuario

Instruction Sheet

*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

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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.te.com

408-8917

PRO-CRIMPER* III Hand Crimping

Tool Assembly 91387-1

With Die Assembly 91387-2 16 MAR 12 Rev B

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.

‡ Included with die assembly and available separately. † Included with tool assembly and available separately.

Figure 1

1. INTRODUCTION

PRO-CRIMPER III Hand Tool Assembly 91387-1

consists of PRO-CRIMPER III Hand Tool Frame

354940-1 and Die Assembly 91387-2. The tool

assembly is used to crimp the contacts listed in

Figure 1. For contact part numbers, contact

PRODUCT INFORMATION at the number at the

bottom of this page.

Read these instructions thoroughly before using the

tool assembly.

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Figures are not drawn to scale.

For additional information on the hand tool frame, refer

to 408-9930.

Reasons for reissue of this instruction sheet are

provided in Section 9, REVISION SUMMARY.

2. DESCRIPTION (See Figure 1)

The tool consist of a stationary jaw and handle, a

moving jaw and handle, and an adjustable ratchet that

ensures full crimping. The tool features a ratchet

adjustment wheel for adjusting the crimp height.

The die assembly consists of a wire anvil, insulation

anvil, wire crimper, and insulation crimper. When

closed, the dies form two crimping chambers. Each

die is held in the tool frame by a single screw.

Die Assembly

Moving Jaw

Ratchet Adjustment

Wheel

Stationary Jaw

Back of Tool Frame

(Wire Side)

Pivot Pin

Ratchet

PRO-CRIMPER III Hand Tool

Frame 354940-1 (408-9930)

Stationary Handle

Moving 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 the appropriate Application Specification (114-series),

but may not comply with other feature parameters of the specification.

TE Connectivity offers a variety of tools to satisfy your performance requirements.

For additional information, contact the Tooling Assistance Center at 1-800-722-1111.

Die Retaining Screw

(2 Places)

Locator Assembly

Additional Contact Support

DIE

ASSEMBLY

LOCATOR

ASSEMBLY ‡

ADDITIONAL

CONTACT

SUPPORT †

PRODUCT FAMILY

WIRE

SIZE

(mm [in.])

INSULATION

DIAMETER (mm [in.])

STRIP LENGTH

(mm [in.])

91387-2 58516-1 679277-1 4.2 mm Contact System 26-22 1.19-1.75 [.047-.069] 2.79-3.30 [.110-.130]

NOTE

408-8917

2of 5

Rev B

Figure 2

Attached to the outside of the tool frame is a locator

assembly, which includes a locknut and moveable

locator. An additional contact support is secured to the

locator assembly by a screw. A nut is used on a die

retaining screw to hold the locator assembly in place.

3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY

AND LOCATOR ASSEMBLY

1. Close the tool handles until the ratchet releases,

then allow the handles to open fully. Remove the

two die retaining screws from the tool jaws.

2. Place the wire anvil and insulation anvil with the

chamfered edges and marked surfaces facing

outward in the moving jaw of the tool frame as

shown in Figure 2, and align the retaining holes in

each die with the associated hole in the tool.

3. Insert two die retaining pins into the holes in the

tool and through the holes in 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 with

the chamfered edges and marked surfaces facing

outward in the stationary jaw of the tool frame as

shown in Figure 2, and align the retaining holes in

each die with the associated hole in the tool.

6. Insert two die retaining pins into the holes in the

tool and through the holes in 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 has

engaged sufficiently to hold the anvils and crimpers

in place, then tighten both die retaining screws.

9. Place the locator assembly and the additional

contact support over the end of the long screw, and

position the locator assembly against the side of the

tool jaw. Refer to Figure 2.

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

The contact support is preset prior to shipment, but

minor adjustment may be necessary as described

in Paragraph 5.1, Contact Support Adjustment.

Also, this tool is provided with a crimp adjustment

feature. Refer to Paragraph 5.2, Ratchet

Adjustment. Initially, the crimp height should be

verified as specified in Section 6, CRIMP HEIGHT

INSPECTION, before using the tool.

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 the wire

strands. Identify the appropriate crimping chamber

according the wire size markings on the die assembly.

Then proceed with the following.

Wire

Crimper

Long Die

Retaining

Screw

Jaws

Screw

Locknut

Chamfered

Edge (Ref)

Offset (Ref)

Wire

Anvil Insulation

Anvil

Insulation

Crimper

Movable

Locator

Die Retaining

Pins

Short Die

Retaining

Screw

Additional Contact Support Retaining

Holes

NOTE

408-8917

3of 5

Rev B

1. Close the tool handles until the ratchet releases,

then allow the handles 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 crimping chamber.

3. Position the contact so that the open “U" of the

insulation barrel faces 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 of the 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 the

insulation barrel or wire barrel.

5. Insert stripped wire into the contact insulation

barrel and wire barrel until it is butted against the

wire stop as shown in Figure 3.

6. Holding the wire in place, squeeze tool handles

together until the ratchet releases. Allow the tool

handles to open, and remove the crimped contact.

The crimped contact may stick in the crimping area,

but can be easily removed by pushing downward

on the top of the locator (see Figure 3).

7. Inspect the crimp according to Section 6, CRIMP

HEIGHT INSPECTION.

DO NOT use defective or damaged contacts. Cut

the contact from the wire and use a new contact.

5. ADJUSTMENTS

5.1. Contact Support Adjustment

Make a sample crimp and determine if the contact

is straight, bending upward, or bending downward.

2. If the contact is bending upward or downward,

loosen the screw that holds the contact supports

onto the locator assembly. See Figure 3.

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 additional contact support

touches the contact.

The ratchet has detents that create audible clicks

as the tool handles are closed.

4. Slightly loosen the nut that holds the locator

assembly onto the tool frame.

5. Move the contact support and secondary contact

support as required to meet the dimensions given in

Figure 3.

6. Tighten the nut, and close the handles until the

ratchet releases.

7. Remove and inspect the contact. Make another

sample crimp. If the contact is straight, tighten the

screw. If the contact is still being bent during

crimping, repeat the adjustment procedure.

5.2. Ratchet Adjustment

The tool ratchet mechanism features an adjustment

wheel with numbered settings. The adjustment wheel

controls the amount of handle pressure exerted on the

jaws during crimping. If the crimp is not acceptable,

adjust the ratchet as follows.

Figure 3

CAUTION

NOTE

CAUTION

NOTE

Back of

Tool

Wire

Locator Assembly

Screw That Holds

Contact Supports

4.39 mm

[.173 in.]

4.78 mm

[.188 in.]

Wire Strip

Length

Movable

Locator in

Contact Slot

Wire Against

Wire Stop

Die

Nest

Additional

Contact Support Contact Support

Locator

Tool

Jaw

408-8917

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Rev B

1. Remove the lockscrew from the ratchet

adjustment wheel. Refer to Figure 4.

2. Using a screwdriver, adjust the ratchet wheel

from the front 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-install the lockscrew.

Figure 4

5. Make a sample crimp. If the crimp is acceptable,

the adjustment setting is correct. If the crimp is

unacceptable, continue to adjust the ratchet, and

again measure a sample crimp.

6. CRIMP HEIGHT INSPECTION

Crimp height inspection is performed using a

micrometer with a modified anvil, commonly referred

to as a crimp height comparator. Refer to instruction

sheet 408-7424 for detailed information on obtaining

and using a crimp height comparator. Proceed as

follows:

1. Refer to Figure 5 and select a maximum size wire

for each crimping chamber.

2. Crimp the contacts according to Section 3,

CRIMPING PROCEDURE.

3. Using the crimp height comparator, measure the

wire barrel crimp height as shown in Figure 5. If the

crimp height conforms to the dimension given, the

tool is considered dimensionally correct. If not, the

tool must be adjusted according to Paragraph 5.2,

Ratchet Adjustment.

7. MAINTENANCE AND INSPECTION

7.1. Maintenance

1. Ensure that the tool frame 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 any components.

Figure 5

2. When not in use, keep tool handles closed to

prevent objects from becoming lodged in the dies,

and store in a clean, dry area.

3. Remove all lubrication and accumulated film from

the dies by immersing the dies in a suitable

commercial degreaser.

7.2. Visual Inspection

1. Inspection of the tool and dies should be made on

a regular basis to ensure that they have not become

worn or damaged.

2. Make sure that the proper die retaining screws

are properly secured.

3. Inspect the crimping chambers of the die

assembly for flattened, chipped, worn, or broken

areas. If damage or abnormal wear is evident, the

dies must be replaced. Refer to Section 8.

8. REPLACEMENT AND REPAIR

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, tool assembly, and die assembly

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 (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

9. REVISION SUMMARY

Revisions to this instruction sheet include:

•Changed company name and logo

Screwdriver

Lockscrew

RatchetAdjustment

Wheel

DIE

ASSEMBLY

MAXIMUM

WIRE SIZE

(AWG)

CRIMPING

CHAMBER

(Wire Size

Marking)

DIMENSION A

(mm [in.])

CRIMP HEIGHT

±0.051 [±.002]

91387-2 24 26-24 0.79 [.031]

22 22 0.89 [.035]

Position Point

on Center of

Wire Barrel

Opposite Seam

Modified

Anvil

(See Table)

408-8917

5of 5

Rev B

•Corrected locator assembly part number and

added part number and clarity for additional contact

support

•Updated tooling on last page

PRO-CRIMPER III Hand Tool Frame 354940-1

(Instruction Sheet 408-9930)

SDE-SA 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)

Electro-Hydraulic (BT 3500 Battery-Hydraulic)

Hand Tool Kits 2031400-[ ]

(Customer Manual 409-10095)

“C”-Head Assembly 2031450-1

(Instruction Sheet 408-10311)

Closed Head Assembly 2031460-1

(Instruction Sheet 408-10312)

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