Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO-CRIMPER* III Han Crimping
Tool Assembly 318451-1 with 408-4217
L C B
1 of 5
E 2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. ther products, logos, and company names used are the property of their respective owners.
T LING ASSISTANCE CENTER 1-800-722-1111
PR DUCT INF RMATI N1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
30 APR 09 Rev B
Die Assembly 318451-2
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
The PR -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 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.
Ratchet
Adjustment Wheel
PR -CRIMPER III Hand
Crimping Tool Frame
354940-1 (408-9930)
Stationary
Handle
Moving Handle
Stationary
Jaw
Die Assembly
318451-2
Moving
Jaw
Figure 1
Back of Tool
(Wire Side)
1. INTRODUCTION
PRO–CRIMPER III Hand Crimping Tool Assembly
318451–1 consists of Die Assembly 318451–2 and
PRO–CRIMPER III Hand Crimping Tool Frame
354940–1. The hand tool assembly is used to crimp
75–Ohm RF Series BNC Commercial Plug Connector
221185–8 and Bulkhead Jack Connector 221221–5
onto various sizes of RG/U cable.
For connector assembly and cable stripping
procedures, refer to instruction sheet 408–9088 for
the plug connectors and 408–9089 for the jack
connectors. Read these instructions thoroughly
before using the hand tool assembly. This document
supersedes Instruction Sheet 408–9282.
Dimensions on this sheet are in millimeters
[with inches in brackets]. Figures are for
reference only and are not drawn to scal
Reasons for reissue of this instruction sheet are
provided in Section 9, REVISION SUMMARY.
2. DESCRIPTION (Figures 1 and 2)
The hand tool assembly features a tool frame with a
stationary jaw and handle, a moving jaw, a moving
handle, and an adjustable ratchet that ensures full
connector crimping.
The tool frame holds a die assembly with two
crimping chambers. The die assembly features a wire
anvil, an insulation anvil, a wire indenter, and an
insulation indenter. Die retaining pins and die retaining
screws are used to position and secure the dies in the
tool frame.
NOTE
i

408-4217
PRO-CRIMPER III H nd Crimping Tool Assembly 318451-1
Rev B2 of 5 Tyco Elect onics Co po ation
Figure 2
Die Retaining
Sc ews
Die Retaining
Pins
Wi e
Indente
Wi e
Anvil
Insulation
Anvil
Insulation
Indente
Fe ule C imping
Chambe
Cente Contact
C imping Chambe
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY
(Figu e 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
screw just enough to hold the dies in place. Do
not
tighten the screw completely at this time.
5. Place the wire indenter and insulation indenter
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 indenter 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 indenters align properly.
Continue closing the tool handles until the ratchet
in the tool frame has engaged sufficiently to hold
the anvils and indenters in place, then tighten both
die retaining screws.
9. To remove, close the tool handles until the
ratchet releases, remove the two die retaining
screws and the four die retaining pins, and slide
the anvils and indenters out of the tool jaws.
4. CRIMPING PROCEDURE
This tool is provided with a crimp ad ustment
feature. Initially, the crimp height should be
verified as specified in Figures 5 and 6. Refer to
Section 5, INSPECTION, and Section 6, CRIMP
HEIGHT ADJUSTMENT, to verify crimp before
using the tool to crimp desired connectors and
wire sizes
Slide the ferrule onto the cable and strip the cable
according to the dimensions provided in the
instructions packaged with the connector. Take care
not to nick or cut wire strands. Proceed as follows:
4.1. Center Cont ct (Figu e 3)
1. Slide center contact onto stripped conductor.
Insert center contact assembly into the partially
closed center contact crimping chamber on the
anvil die. Make sure the center contact flange is
against the edge of the die as shown in Figure 3.
2. While holding the cable in place, crimp the
center contact by closing the tool handles until the
ratchet releases.
3. Allow the handles to open fully, and remove the
crimped center contact from the die assembly.
NOTE
i

408-4217
PRO-CRIMPER III Hand Crimping Tool Ass mbly 318451-1
3 of 5Rev B
T co Electronics Corporation
Figure 3
Center Contact
Flange Against
Edge of Die
Anvil Die
Stripped Cable
Center Contact Crimp
4.2. F rrul (Figure 4)
1. Flare the cable braid and insert the crimped
center contact into the connector body until the
cable dielectric is against the dielectric inside the
connector body. The flared braid will then fit over
the support sleeve of the connector body.
2. Slide the ferrule forward over the braid until the
ferrule is against the connector body.
3. Place the ferrule in the crimping chamber on the
anvil die so that the shoulder of the connector body
is against the edge of the die. Refer to Figure 4.
4. Holding the assembly in place, close the tool
handles until the ratchet releases.
5. Allow the handles to open fully, and remove the
crimped assembly from the die assembly.
Da aged contacts should not be used. If a
da aged contact is evident, it should be cut fro
the wire and replaced with a new one. Contacts
should not be reter inated.
5. INSPECTION
5.1. Visual Insp ction
The crimping dies should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimping chambers for
flattened, chipped, worn, or broken areas. If damage
or abnormal wear is evident, the tool must be
replaced. See Section 8, DIE REPLACEMENT.
5.2. P riodic Insp ction
A. C nt r Contact Crimp H ight Insp ction
This inspection requires the use of a micrometer with
a modified anvil as shown in Figure 5.
Tyco Electronics does not anufacture or arket
these gages. However TE reco ends the
odified icro eter (Cri p Height Co parator
RS-1019-5LP).
Proceed as follows to check the crimp height of the
center contact:
1. Select the center contact for the connector.
Figure 4
Anvil Die
Ferrule
Ferrule Crimp
Connector Shoulder
Against Edge of Die
Cross-Sectional
View
Anvil Die
CAUTION
!
NOTE
i

408-4217
PRO-CRIMPER III Hand Crimping Tool Assembly 318451-1
Rev B4 of 5 Tyco Electronics Corporation
Figure 5
1.0287-1.1811
[.0405-.0465]
Position Point
on Center of
ire Barrel
Modified
Anvil
Measuring Center Contact Crimp Height
2. Refer to Section 4, CRIMPING PROCEDURE,
and crimp the center contact accordingly.
3. Using a crimp height comparator, measure the
crimp height as shown in Figure 5. If the crimp
height conforms to that shown, the die assembly is
considered dimensionally correct. If not, return the
dies to Tyco Electronics for evaluation and repair
(refer to Section 8, DIE REPLACEMENT).
B. Gaging the Ferrule Crimping Chamber
This inspection requires the use of a plug gage
conforming to the dimensions in Figure 6. Tyco
Electronics does not manufacture or market these
gages. To gage the ferrule crimping chamber,
proceed as follows:
1. Close the jaws until the dies have bottomed,
then HOLD the frame handles in this position. Do
NOT force the dies beyond initial contact.
R
NO-GO DIM.GO DIM.
Suggested Plug Gage for
Ferrule Crimping Chamber
CRIMP
ECTION
GAGE ELEMENT
DIMEN ION RADIU
(
Max
)
WIDTH
(
Max
)
ECTION
GO NO-GO
(Max)
R"
(Max)
W"
Ferrule 4.1910-4.1986
[.1650-.1653] 4.4424-4.4450 [.1749-.1750] 2.032 [.080] 4.064 [.160]
Insulation
Ferrule 2.4130-2.4206 [.0950-.0953] 2.8676-2.8702 [.1129-.1130] 1.016 [.040] 2.286 [.090]
Figure 6
2. Align the GO element with the ferrule crimping
chamber. Push the element straight into the
crimping chamber without using force. The GO
element must pass completely through the
crimping chamber.
3. Align the NO–GO element and try to insert it
straight into the same crimping chamber. The
NO–GO element may start entry, but must not
pass completely through.
4. Repeat Steps 2 and 3 for the insulation ferrule
section of the crimping chamber.
Insert the gage element for the insulation ferrule
section into the back of the crimping chamber.
The GO element for this section will not pass
completely through the crimping chamber.
6. CRIMP HEIGHT ADJU TMENT (Figure 7)
The frame assembly ratchet mechanism features an
adjustment wheel with numbered settings. If the crimp
height 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 opposite side of the frame.
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.
5. Make a sample crimp and measure the crimp
height. If the crimp height is acceptable, secure the
lockscrew. If the dimension is unacceptable,
remove lockscrew and continue to adjust the
ratchet, and again measure a sample crimp.
Figure 7
Screwdriver
Ratchet
Adjustment
heel
Lockscrew
(Typ)
NOTE
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408-4217
PRO-CRIMPER III Hand Crimping Tool Assembly 318451-1
5 of 5Rev B
Tyco Electronics Corporation
7. 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.
8. REPLACEMENT
Customer–replaceable parts and dies are shown in
Figure 8. Spare parts or the die assembly should be
stocked and controlled to prevent lost time when die
replacement is necessary.
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.
Order 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
For customer repair service, contact a Tyco
Electronics Representative at 1–800–526–5136.
9. RE ISION SUMMARY
Since the previous release of this instruction sheet,
the following change were made:
S TE logo was applied; and
S The format was updated to the current
corporate requirements.
g 1.04-1.17
[.041-.046]
2.64 +0.20
[.104 +.008]
4.32 +0.10
[.170 +.004]
47.62
[1.88]
11.63
[.458]
Weight: 227 g [8 oz]
1
2
3
4
5
g One side can go 0.064 [.0025] out of tolerance as long as the average
measurements of oth sides are within dimension s
p
ecified.
CUSTOMER-REPLACEABLE PARTS FOR DIE ASSEMBLY 318451-2
ITEM PART NUMBER DESCRIPTION QTY PER
ASSEMBLY
1 318432-1 INDENTER, Wire 1
2 318430-1 ANVIL, Wire 1
3 318431-2 INDENTER, Insulation 1
4 318429-2 ANVIL, Insulation 1
5 679231-1 PIN, Die Retaining 4
Figure 8