Tyco Electronics AMP PRO-CRIMPER III User manual

Instruction Sheet
PRO–CRIMPER III
Hand Crimping Tool Frame 408–9930
E 2004 Tyco Electronics Corporation, Harrisburg, PA
AllInternationalRightsReserved
AMP and Tyco are trademarks. *Trademark
Other products, logos, and company names used are the property of their respective owners. LOC B
1 of 4
TOOLINGASSISTANCECENTER1–800–722–1111
FAX/PRODUCTINFO1–800–522–6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
This controlled document is subject to change.
For latest revision, call the FAX/PRODUCT INFO number.
02 JUN 04 Rev B
Assembly 354940–1
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended–use, production operations is available.
Figure 1
StationaryJaw
MoveableJaw
Emergency
Ratchet
Release
Ratchet
Adjustment
Wheel
Pivot Pin
Ratchet
Adjustment
Screw
DieRetaining
Screws
1. INTRODUCTION
This instruction sheet provides application and
maintenance procedures for the PRO–CRIMPER III
Hand Crimping Tool Frame Assembly 354940–1. See
Figure 1. The tool is designed to accept
interchangeable crimping die assemblies for crimping
various types of Tyco Electronics Connectors.
In most cases, the PRO–CRIMPER III tool frame
assembly is provided with a specific set of dies and is
considered a component part of a crimping assembly.
Refer to the appropriate instruction sheet packaged
with the hand tool/crimping die assembly, or with the
separate die assembly, for information regarding
crimping procedures, crimp height inspection, and
crimping die gaging.
Read these instructions thoroughly before installing
dies and using the tool.
The PRO–CRIMPER III Frame Assembly is
designed to accept dies to crimp a variety of Tyco
Electronics products. Contact your local Tyco
Electronics Representative or the Tooling
AssistanceCenter for informationregarding the
availability of dies for specific applications.
All dimensions on this document are in metric
units [with U. S. customary units in brackets].
Figures and illustrations are for reference only
and are not drawn to scale.
Reason for revision is given in Section 7, REVISION
SUMMARY.
2. DESCRIPTION
The PRO–CRIMPER III tool consists of two crimping
jaws, an adjustable ratchet, spring–actuated handles,
two die retaining screws, and an emergency ratchet
release. The slotted design of the crimping jaws
permits easy installation and removal of crimping
NOTE
NOTENOTE

408–9930
PRO–CRIMPER III Hand Crimping Tool Frame Assembly354940–1
Rev B2 of 4
dies. The adjustable ratchet allows handle pressure to
be set for optimum crimping die performance.
3. DIE INSTALLATION AND REMOVAL
Select the desired die assembly, remove the die
retention screws from the tool jaws, and proceed as
follows:
3.1. Shouldered Dies (Figure 2)
1. Place the upper die in the stationary jaw of the
tool frame.
Figure 2
UpperDie
LowerDie
CenterContact
CrimpSection
DieRetention
Screws
2. Insert a die retention screw through the jaw and
die and tighten the screw so that the die is held in
place, but do not tighten the screw completely at
this point.
Die assemblies with center contact crimp
sections should be installed with the center
contact crimp section toward the front of the tool
jaws as shown in Figure 2. If indicated otherwise
in other instructions, follow the specific die
requirementsdemonstrated in that document.
3. Place the lower die in the moving jaw of the tool
frame. Install a die retention screw through the jaw
and die and tighten the screw so that the die is
held in place, but do not tighten the screw
completely at this point.
The PRO–CRIMPER III tool ratchet has detents
that are audible as seven “clicks” as the handles
are closed. The ratchet releases on the seventh
“click”.
4. Slowly close the tool handles, allowing the dies
to mate and/or align. Continue closing the tool
handles until the ratchet makes the sixth “click,”
then tighten both die retention screws until snug.
5. To remove the die assembly, close the tool
handles until the ratchet releases, and allow the
handles to open fully. Loosen and remove the die
retention screws and slide the dies out of the tool
jaws.
3.2. Pinned Dies (Figure 3)
1. Install the wire and insulation anvil dies, with the
chamfers facing the front of the tool, and with the
die markings facing outward, into the movable jaw
of the frame assembly.
2. Insert the die retaining pins and the short die
retention screw. Do
not tighten the screw
completely.
3. Install the wire and insulation crimper dies, with
the chamfers facing the front of the tool, and with
the die markings facing outward, into the stationary
jaw of the frame assembly.
4. Insert the die retaining pins the long die
retention screw. Do not tighten the screw
completely.
Figure 3
Locator Long(M4x25)
Retention
Screw
Short(M4x12)
Retention
Screw
DieRetaining
Pins (2 of 4)
Chamfer
AnvilDies Crimper Dies
Chamfer
Nut
5. Slowly close the tool handles, allowing the dies
to mate and/or align. Continue closing the tool
handles until the ratchet makes the sixth “click,”
then tighten both die retention screws until snug.
6. Install the locator assembly and tighten the hex
nut.
7. Reverse the procedure to remove the die
assembly.
NOTE
NOTE

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PRO–CRIMPER III Hand Crimping Tool Frame Assembly354940–1
3of 4Rev B
4. MAINTENANCE/INSPECTION
4.1. Daily Maintenance
Tyco Electronics recommends that operators of the
tool be made aware of, and 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 pivot 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
SAE No. 20 motor oil. Do not oil excessively.
4. When the tool is not in use, keep handles closed
to prevent objects from becoming lodged in the
crimping jaws. Store the tool in a clean, dry area.
4.2. Periodic Inspection
Regular inspections of the tool should be performed
by quality control personnel. A record of scheduled
inspections should remain with the tool or be supplied
to supervisory personnel responsible for the tool.
Inspection frequency should be based upon amount
of use, working conditions, operator training and skill,
and established company standards.
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 all pivot pins are in place and
secured with retaining rings.
3. Close tool handles until ratchet releases and
then allow them to open freely. If they do not open
quickly and fully, the spring is defective and must
be replaced. See Paragraph 6, PARTS
REPLACEMENT.
4. Inspect the tool frame for wear or damage,
paying particular attention to the tool jaws and
pivot points. If damage is evident, refer to
Paragraph 6, PARTS REPLACEMENT. If tool is
acceptable, lubricate and return to service.
This tool is recommended for R&D prototyping,
networkingapplications,commercial/industrial
maintenance, and field service repair. For other
applications, please contact your Tyco Electronics
Sales Representative or the Customer Tooling
AssistanceCenterat 1–800–722–1111.
5. CRIMP HEIGHT ADJUSTMENT
The tool frame assembly features a ratchet
mechanism and adjustment wheel with a range of
settings. The ratchet mechanism ensures that the tool
has completed the cycle. The adjustment wheel
controls the amount of handle pressure exerted on
the tool jaws and crimping dies during the crimping
procedure. Although the ratchet is preset prior to
shipment, it is important that you verify the crimp
height. Also, general use and subsequent wear may
cause the tool to go out of adjustment. It is
recommended that the crimp height be inspected —
and adjusted, if necessary — on a regular basis by
quality control personnel.
This is a general explanation of the procedure.
For specific information, refer to the instruction
sheet packaged with the die assembly.
1. Crimp a contact onto a properly–prepared wire
of the correct size.
2. If the crimp height is greater than
recommended, remove the ratchet wheel
adjustment screw and rotate the adjustment wheel
COUNTERCLOCKWISE to a higher setting.
Repeat as required.
3. If the crimp height is less than recommended,
remove the ratchet wheel adjustment screw and
rotate the adjustment wheel CLOCKWISE to a
lower setting. Repeat as required.
4. If the crimp cannot be made to conform to the
dimensions provided in the appropriate product
application specification, the tool and/or dies are
defective and must be replaced.
6. PARTS REPLACEMENT
PRO–CRIMPER III Hand Crimping Tool Frame
Assembly 354940–1 is inspected prior to shipment. It
is recommended that it be inspected upon arrival to
ensure that it has not become damaged during
shipping.
Refer to the parts list in Figure 4 to determine the part
number for the item to be replaced and to identify the
proper location and orientation of the part in the tool
frame.
Additional tools and parts may be ordered from:
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
7. REVISION SUMMARY
Per EC 0990–0647–04:
S Updated document to corporate requirements
S Changed PRO–CRIMPER “II” to “III” in all
instances
NOTE
NOTE

408–9930
PRO–CRIMPER III Hand Crimping Tool Frame Assembly354940–1
Rev B4 of 4
3
1
2
4
5
6
7
8
9
11
10
12
PRO–CRIMPER REPAIR KIT 679221–1 D
ITEM DESCRIPTION QTY PER KIT ITEM DESCRIPTION QTY PER KIT
1SCREW, Die Retaining, M4 x 12 2 7 PIN, Pivot 3
2SCREW, M3 x 5 1 8 PIN, Pawl 3
3RING, Retaining 7 9 PAWL, Ratchet 3
4RING, Retaining 2 10 PIN, Die Retaining 4
5SPRING, Extension 111 SCREW, Die Retaining, M4 x 25 1
6SPRING, Extension 1 12 NUT, M4 1
D Parts are NOT available individually
Figure 4