Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand 408--10320
LOC B
1of 4
E2009 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
01 SEP 09 Rev ACrimping Tool Assembly 1976200- [ ]
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.
PRO--CRIMPER III hand crimping tool is a “Commercial” grade and is
designed primarily for field installation, repair, maintenance work, and
prototyping in industrial, commercial, and 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 document. A variety of tools are offered to
satisfy performance requirements. For additional information, contact the
Tooling Assistance Center at the number at the bottom of this page.
Die Assembly
Moving
Jaw
Ratchet Adjustment
Wheel
Moving Handle
Stationary Handle
PRO--CRIMPER III Hand
Crimping Tool Frame 354940--1
Pivot Pin
Back of Tool
Stationary
Jaw
S
E
C
U
R
E
CABLE
HAND TOOL
ASSEMBLY
DIE
ASSEMBLY
S
E
C
U
R
E
MODULAR
PLUG OUTSIDE
DIAMETER
CONDUCTOR
SIZE (AWG)
CONDUCTOR
INSULATION
DIAMETER (mm)
STRIP
LENGTH
1976200--1 1976200--2
Contact Product
Information or Tooling
Assistance Center
(See Bottom of Page)
5--6 mm
[.197--.236] 26--24 2.03--2.54 [.080--.100]
35.0+5.0
[1.38 +.02]
1976200--3 1976200--4
Contact Product
Information or Tooling
Assistance Center
(See Bottom of Page)
6--7 mm
[.236--.275] 26--24 2.03--2.54 [.080--.100]
35.0+5.0
[1.38 +.02]
Figure 1
1. INTRODUCTION
PRO--CRIMPER III Hand Crimping Tool Assembly
1976200--[ ] consists of PRO--CRIMPER III Hand Tool
Frame 354940--1 and Die Assemblies listed in
Figure 1.
The tool assembly is used to crimp the contacts, and
the internal and external strain reliefs of the Secure
Modular Plugs listed in Figure NO TAG.
Read these instructions thoroughly before using the
hand tool assembly.
Dimensions in this instruction sheet are in
millimeters and [inches in brackets]. Figures and
illustrations are for reference only and are not
drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
2. DESCRIPTION
The tool frame features a stationary jaw and handle, a
moving jaw and handle, and an adjustable ratchet that
ensures full crimping. The tool frame holds the die
assembly. Refer to Figure 1.
NOTE
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408- 10320
PRO- CRIMPER III Hand Crimping Tool Assembly 1976200- [ ]
Rev A2 of 4 Tyco Electronics Corporation
The die assembly consists of an insulation stuffer,
wire stuffer, housing support, housing guides, and
mounting and retaining hardware.
3. INSTALLATION AND REMOVAL OF
DIE ASSEMBLY
1. Close the tool handles until the ratchet releases,
then allow the handles to open fully. If present,
remove both retaining screws from the tool frame.
2. Orient the insulation stuffer as shown in
Figure 2, and insert it into the stationary jaw of the
tool frame. Align the holes with the associated
holes in the tool frame. Insert the short retaining
pins and short retaining screw into the holes in the
tool frame. Tighten the screw.
3. Orient the housing support as shown in
Figure 2, and insert it into the stationary jaw of the
tool frame. Align the holes with the associated
holes in the tool frame. Insert the short retaining
pins and short retaining screw into the holes in the
tool frame. Tighten the screw.
4. Carefully close the tool handles, making sure
that the parts align properly.
5. To disassemble, close the tool handles until the
ratchet releases. Remove the screws, retaining
pins, housing support, and insulation stuffer out of
the tool frame jaws.
4. CRIMPING PROCEDURE
Before proceeding, refer to the applicable Application
Specification 114--13035 and ensure the following:
— the modular plug and cable are compatible
— the cable polarity is properly maintained
— the modular plug is properly crimped and
assembled
Make sure that the modular plug shield is fully
bottomed onto the body. With some cables
containing shielded twisted pairs,thisis
especially IMPORTANT to check.
1. Close the tool handles until the ratchet releases,
then allow the handles to open FULLY.
2. Hold the tool so that the back is facing you.
Insert the modular plug (including shield and cable)
in the crimping chamber until it bottoms. Refer to
Figure 3.
Figure 2
Insulation
Stuffer
Retaining
Screw
Retaining Screw
Retaining Pin
(2 Places)
Retaining Pin
(2 Places)
Housing
Support
Tool Frame
Wire Stuffer
(Ref)
Socket Head Cap
Screw (Retains
Wire Stuffer Ref)
Strain Relief
Depressor
CAUTION
!

408- 10320
PRO- CRIMPER III Hand Crimping Tool Assembly 1976200- [ ]
3of 4Rev ATyco Electronics Corporation
Figure 3
Modular Plug Bottomed
in Crimping Chamber
Housing
Support
Insulation
Stuffer
Wire Stuffer
3. While holding the assembly, carefully close the
tool handles until the ratchet releases, then allow
the handles to open FULLY.
This tool terminates 3 areas of the modular plug.
For proper alignment, make sure to apply forward
pressure on the cable while closing the tool
handles.
4. Remove the modular plug from the tool, and
make sure that the crimp requirements are met
according to the applicable application specification
(refer to first paragraph of Section 4).
If necessary, adjust the tool ratchet according to
Paragraph 5.1 to obtain the proper crimp height.
Crimp Height Gage 904170--1 is to be used as a
quick verification of acceptable crimp height as
shown in Figure 4. Refer to Instruction Sheet
408--4389 for instructions on using the gage.
Figure 4
Crimp Height
Gage (Ref)
Modular Plug
(Ref)
Checking Crimp Height
5. ADJUSTMENTS
5.1. Ratchet Adjustment (Figure 5)
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:
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With 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--assemble the lockscrew.
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. If a proper crimp
cannot be obtained, the tool or die assembly must
be replaced. Refer to Section 7.
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
Figure 5
5.2. Wire Stuffer Adjustment
If the wire stuffer is not assembled onto the insulation
stuffer or if correct alignment of these two parts is
unsure, proceed with the following:
1. Install the wire stuffer onto the insulation stuffer
using the 4--40 UNC¢.621 in. socket head cap
screw included with the die assembly. Refer to
Figure 2.
NOTE
i
NOTE
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408- 10320
PRO- CRIMPER III Hand Crimping Tool Assembly 1976200- [ ]
Rev A4 of 4 Tyco Electronics Corporation
DO NOT tighten the screw. If the screw is tight,
loosen it.
2. Close the tool handles until the ratchet releases,
then allow the handles to open FULLY. Insert a
modular plug (without cable) into the crimping
chamber.
3. Close the tool handles, and hold.
4. Insert a key into the socket head cap screw
(retaining the wire stuffer), and tighten the screw.
5. Allow the handles to open, and remove the
crimped modular plug. The wire stuffer will be held
in its proper position.
6. MAINTENANCE AND INSPECTION
6.1. Daily Maintenance
It is recommended that the tool operator be made
aware of, and are responsible for, the following steps
of daily maintenance.
1. Remove dust, moisture, and any other
contaminants from the tool with a clean, soft brush,
or a clean, soft, lint--free cloth. DO NOT use hard
or abrasive objects that could damage the tool.
2. Make certain that the retaining pins are in place
and that they are secured with retaining rings.
3. All pins, pivot points, and bearing surfaces
should be protected with a thin coat of any good
grade SAE 20 motor oil. DO NOT oil excessively.
4. When the tool is not in use, keep the handles
closed to prevent objects from becoming lodged in
the jaws.
5. Store the tool in a clean, dry area.
6.2. Periodic Inspection
Regular inspection of the tool should be performed by
quality control personnel. A record of the scheduled
inspections should remain with the tool or be supplied
to personnel responsible for the tool. Inspection
frequency should be based on amount of use,
working conditions, operator training and skill, and
established company standards.
6.3. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the tool (handles partially closed) in a
suitable commercial degreaser that will NOT affect
paint or plastic material.
2. Make certain that the retaining pins are in place
and that they are secured with retaining rings.
3. Close the tool handles until the ratchet releases,
and then allow the handles to open freely. If they
do not open quickly and fully, the spring is
defective and must be replaced.
4. Inspect the tool frame for wear or damage,
paying particular attention to the tool jaws and the
pivot points. If damage is evident, replace it. If
damage is not evident, lubricate the pivot point and
return the tool to service.
5. Check the die assembly on a regular basis to
ensure it has not become worn or damaged.
Inspect the crimping sections for flattened,
chipped, worn, or broken areas. If damage is
evident, replace the die assembly.
7. 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 die
assembly is damaged or worn excessively, it must be
replaced. Order the 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 (038--035)
Tyco Electronics Corporation
PO Box 3608
Harrisburg PA 17105--3608
8. REVISION SUMMARY
Revisions to this instruction sheet include:
SInitial release of document
NOTE
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