Under Carpet PRO-CRIMPER II Hand Tool Assembly 91384-1

2003 Tyco Electronics Corporation, Harrisburg, PA This controlled document is subject to change.
All International Rights Reserved
For latest revision, call the FAX/PRODUCT INFO number.
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Under Carpet
Instruction Sheet
PRO–CRIMPER* II 408–8860
Hand Tool Assembly 91384–1
02 DEC 03 Rev O
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.
The PRO–CRIMPER II 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.
TERMINAL FAMILYY
Lower Die
Moving Jaw
Moving Handle
Stationary Jaw
Pivot Pin
CABLE TYPE OF APPLICATION
Stationary Handle
SIZE (AWG) TAP CONNECTOR SPLICE CONNECTOR
Under Carpet Connectors 10–12 553455–2 553454–1
1. INTRODUCTION
Under Carpet PRO–CRIMPER II Hand Tool Assembly
91384–1, which is designed to terminate tap and
splice connectors onto 10 and 12 AWG Under Carpet
power cables (see Figure 2), consists of a lower die
installed in a modified PRO–CRIMPER hand tool
frame.
NOTE
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.
Figure 1
Reasons for reissue are provided in Section 8,
REVISION SUMMARY.
2. DESCRIPTION
The tool features a tool frame with a stationary jaw
and handle, a moving jaw, and a moving handle. See
Figure 1.
3. TERMINATION PROCEDURE (Figure 3)
Refer to the table in Figure 1 and select a connector
(tap or splice) for the cable size and type of
application to be terminated. Separate the conductors
along the perforations as indicated in Figure 2.
TOOLING ASSISTANCE CENTER 1–800–722–1111
FAX/PRODUCT INFO 1–800–522–6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
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LOC B

50.8 [2.000]
152.4 [6.000]
2 of 3
Splice Connector
3.18 [.125] (Refer to Instruction Sheet
408–3128)
Cover (Typ)
Tap Connector
(Refer to Instruction Sheet
408–3127)
3.18 [.125]
Figure 2
Under Carpet PRO–CRIMPER II Hand Tool Assembly 91384–1
Terminating
Tines (Typ)
152.4 [6.000]
Figure 3
CAUTION
Proceed as follows:
408–8860
Before starting termination, refer to the instruction
sheets packaged with the tap and splice
connectors for preparation procedures and
assembly sequence. The applicable sheets are
referenced in Figure 2. Failure to do so could
prevent sealing of insulation patches.
1. Make sure flat side of hand tool is parallel with
floor.
2. Gently lift cable and straddle hand tool jaws with
connector and cable.
3. Squeeze tool handles together until the one
handle bottoms on the handle stop.
4. Allow tool handles to open FULLY and remove
hand tool from connector.
5. Repeat Steps 1 through 4 as necessary for one
side of connector and cable.
4. CRIMP HEIGHT ADJUSTMENT
This tool is permanently set to position No. 7. No
adjustment is necessary.
Splice Connector Tap Connector
Rev O

5. MAINTENANCE
Ensure that the tool and lower die is kept 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 lower die, and store in a clean, dry area.
6. VISUAL INSPECTION
The lower die should be inspected on a regular basis
to ensure it has 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 7,
REPLACEMENT.
6.1. Gaging the Crimping Chamber
This inspection requires the use of a GO NO–GO
gage conforming to the dimensions shown in
Figure 4. Tyco Electronics does not manufacture or
market these gages.
Proceed as follows:
1. Close the tool handles until the one handle
bottoms on the handle stop, then HOLD in this
position. Do NOT force the handles beyond initial
contact. Refer to Paragraph 6.2, Tool Closure
Inspection.
2. Align the GO element with the jaws. Push
element straight into the jaws without using force.
The GO element must pass completely through as
shown in Figure 4.
3. Align the NO–GO element and try to insert it
straight into the jaws. The NO–GO element may
start entry but must not pass completely through
as shown in Figure 4.
If the jaws conform to the gage inspection, the tool is
considered dimensionally correct and should be
lubricated with a THIN coat of any good SAE No. 20
motor oil. If not, the tool must be repaired before it is
returned to service.
6.2. Tool Closure Inspection
Squeeze the tool handles together until the one
handle bottoms on the handle stop. The jaws should
bottom properly, and they should conform to the
gaging dimensions as shown in Figure 4.
Rev O
Under Carpet PRO–CRIMPER II Hand Tool Assembly 91384–1
ÍÍÍ
ÍÍÍ
4.06 [.160]
ÍÍÍ
ÍÍÍ
ÍÍÍNO–GO
ELEMENT
76.2 [3.000] Min.
20.32 [.800] Min. (Typ)
6.35 [.250] (Typ)
NO–GO Dim. 1.68 [.066]
7. REPLACEMENT
Suggested Plug Gage Design
NO–GO GO
Figure 4
12.7 [.500]
GO Dim. 1.47 [.058]
ÍÍÍ
ÍÍÍ
ÍÍÍ
ÍÍÍ
ÍÍÍ
408–8860
GO
ELEMENT
Customer–replaceable parts are available separately,
Repair Kit 679221–1 includes a replacement nut and
a variety of pins, rings, screws, and springs. 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
8. REVISION SUMMARY
Per EC: 0990–1208–03
Initial release of document
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