Tyco Electronics PRO CRIMPER III User manual

Instruction Sheet
PRO-CRIMPER* III Hand Crimping
Tool Assembly 224933-1 408-4160
LOC B
1 of 4
E 2009 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.
TOOLI G ASSISTA CE CE TER 1-800-722-1111
PRODUCT I FORMATIO 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
11 MAY 09 Rev A
with Die Assembly 224933-2
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduse ofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Stationary Jaw
Back of Tool
(Wire Side)
Pivot Pin
PRO-CRIMPER III Hand
Crimping Tool Frame
354940-1 (408-9930)
Stationary
Handle
Moving Handle
Locator
Assembly
(Supplied with
Die Assembly)
Front of Tool
(Locator Side)
Die
Assembly
Moving Jaw
Ratchet
Adjustment
Wheel
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 114
series 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.
TE
TE
Connector
Cable
TE
Die Assembly
TE
Locator Assembly
{
Connector
Family
}
Size
(A G) Insulation Diameter Shield Type
I FOPORT*
S
3.43 to 3.81 mm
[.135 to .150 in.] Small
224933-2 58515-1 Series III
Shield Kit 28-32 5.72 x 3.68 mm
[.225 x .145 in.]
OVAL Large
{ Supplied with die assembly. Also available separately.
} Contact the Tooling Assistance Center or Product Information Center (below) for specific
shield part numbers.
Figure 1
1. INTRODUCTION
PRO–CRIMPER III Hand Crimping Tool
Assembly 224933–1 consists of Die Assembly
224933–2 and PRO–CRIMPER III Hand Crimping
Tool Frame 354940–1. The die assembly consists of
crimping dies and a locator assembly.
Read these instructions thoroughly before crimping.
Dimensions on this instruction sheet are in
millimeters [with inch equivalents provided in
brackets]. Figures and illustrations are for
identification only and are not drawn to scale.
NOTE
i

408-4160
PRO-CRIMPER III H nd Crimping Tool Assembly 224933-1
Rev A2 f4 Tyc Electr nics C rp rati n
Figure 2
Nut
L cat r
Insulati n
Crimper
Chamfer
Insulati n
Anvil
Die Retaining Screws
Die Retaining
Pins
T l Frame
L cat r
Assembly
Chamfer
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 an insulation anvil and an
insulation crimper.
Attached to the outside of the frame is a locator
assembly, which contains a locator, a spring retainer,
and a shield 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 insulation anvil so that the chamfered
side faces 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 anvil, and tighten the screw just enough to
hold the anvil in place. Do
not tighten the screw
completely at this time.
5. Place the insulation crimper so that the
chamfered side faces 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 the crimper die, and tighten the
screw just enough to hold the die in place. Do
not
tighten the screw completely at this time.
8. Carefully close the tool handles, making sure
that the anvil and crimper align properly. Continue
closing the tool handles until the ratchet in the tool
frame has engaged sufficiently to hold the anvil
and crimper 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 anvil and
crimper out of the tool jaws.
4. SHIELD SUPPORT ADJUSTMENT (Figure 3)
The shield support is preset prior to shipment, but
minor adjustment may be necessary.
1. Make a sample crimp and determine if the
shield is straight, bending upward, or bending
downward.
NOTE
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408-4160
PRO-CRIMPER III Hand Crimpin Tool Assembly 224933-1
3 of 4Rev A
Tyco Electronic Corporation
Figure 3
Adju tment
Screw for
Shield
Support
Shield Support Locator
Back of Tool
(Wire Side)
Locator
Butted
Again t
In ulation
Barrel
Shield
(Typ)
Crimper
In ulation
Barrel
Anvil
Cable
Shield Cable
2. If adjustment is required, loosen the screw that
holds the shield support onto the locator assembly.
The ratchet has detents that create audible clicks
as the tool handles are closed.
3. Place a shield with wire into the proper nest and
close the tool handles until the ratchet reaches the
sixth click, or until the shield support touches the
shield.
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
5. Move the shield support as required to eliminate
the bending of the shield.
6. Tighten the nut and close the handles until the
ratchet releases.
7. Remove and inspect the shield.
8. Make another sample crimp. If the shield is
straight, tighten the shield support screw. If the
shield is still being bent during crimping, repeat the
adjustment procedure.
5. CRIMPING PROCEDURE
This tool is provided with a crimp adjustment
eature. Initially, the crimp height should be
veri ied as speci ied in Figure 4. Re er to
Section 6, CRIMP HEIGHT INSPECTION, and
Section 7, CRIMP HEIGHT ADJUSTMENT, to
veri y crimp height be ore using the tool to crimp
desired shields and wire sizes.
Prepare the cable, connector, and shields in
accordance with the instructions contained in the
applicable Application Specification. Ensure that cable
drain wire(s) is positioned between the cable
insulation jacket and the insulation crimping barrel of
the lower shield. Refer to the table in Figure 1 to
determine if the shield type (small or large) is
compatible with the cable size and insulation
diameter. Then 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.
2. Holding the shield by the mating end, insert the
shield — insulation barrel first — through the front
of the tool and into the appropriate crimp section.
3. Position the shield so that the mating end of the
shield is on the locator side of the tool, and so that
the open “U” of the insulation barrel faces the top
of the tool. Place the shield up into the nest so that
the movable locator butts against the front end of
the insulation barrel. Refer to Figure 3.
Make sure that both sides o the insulation barrel
are started evenly into the crimping section. Do
NOT attempt to crimp an improperly positioned
shield.
4. Hold the shield in position and squeeze the tool
handles together until ratchet releases.
5. Allow tool handles to open and remove crimped
shield.
The crimped shield may stick in the crimping
area, but the shield can be easily removed by
pushing downward on the top o the locator (see
Figure 3).
6. Check the shield’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.
6. CRIMP HEIGHT INSPECTION
This inspection requires the use of a micrometer with
a modified anvil.
NOTE
i
NOTE
i
CAUTION
!
NOTE
i

408-4160
PRO-CRIMPER III Hand Crimping Tool Assembly 224933-1
Rev A4 of 4 Tyco Electronics Corporation
Tyco Electronics does not manufacture or market
these gages. However TE recommends the
modified micrometer (Crim Height Com arator
RS-1019-5LP) or the digital Mitutoyo
micrometer.
Proceed as follows:
1. Refer to Figure 4 and select a cable (maximum
size) for each crimp section listed.
2. Refer to Section 5, CRIMPING PROCEDURE,
and crimp the shield(s) accordingly.
3. Using a crimp height comparator, measure the
insulation 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.
Position
Point on
Center of
Insulation Barrel
Opposite
Seam
Modified Anvil
A"
Insulation
Diameter
Crimp Section
(Insulation Size
Marking)
Crimp Height
Dim. (A") and
Tolerance (+)
3.43 to 3.81
[0.135 to 0.150 S2.64 +.05 [0.104 +.002
5.72 x 3.68
[0.225 x 0.145
OVAL L3.25 +.05
[0.128 +.002
Figure 4
7. RATCHET (Crimp Height) ADJ STMENT (Figure 5)
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.
Figure 5
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)
4. Replace the lockscrew.
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. VIS AL 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.
10. REPLACEMENT
Customer–replaceable parts are shown in Figure 1.
Available separately, PRO–CRIMPER III Hand
Crimping 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
PO BOX 3608
HARRISBURG PA 17105–3608
11.REVISION S MMARY
Since the previous release of this instruction sheet:
S The TE logo has been applied; and
S The format has been updated.
NOTE
i