Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO-CRIMPER* III

Hand Tool Assembly 790163-[ ] 408-8738

LOC B

of 4

2007 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

31 JUL 07 Rev D

ith Die Assembly 790163-[ ]

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduse ofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

applications. A wide selection of powered application equipment for extended-use, production operations is available.

PRO-CRIMPER III hand 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 Tool

Frame 354940-1

Pivot Pin

Back of Tool

Stationary

Jaw

CABLE

HAND TOOL

ASSEMBLY DIE

ASSEMBLY MODULAR

PLUG

SIZE (A G) CONDUCTOR

INSULATION

DIAMETER (mm)

OUTSIDE

DIAMETER (mm) STRIP LENGTH

(mm)

790163-1 790163-2 336330-1, -2 5.0-6.0

790163-3 790163-4 336349-1 26-24 0.80-1.00 5.0-6.0

790163-5 790163-6 336462-1 6.0-7.0

35 0+5 0

1711413-1, -2 26-24 0.80-1.00

790163-7 790163-8 1933441-[ ] 26-24 0.89-1.09 4.7-5.3

1933442-[ ] 24-23 0.89-1.09

Figure 1

For additional modular plug part numbers, contact PRODUCT I FORMATIO at the bottom of this page.

1. INTRODUCTION

PRO–CRIMPER III Hand Tool Assembly 790163–[ ]

consists of PRO–CRIMPER III Hand Tool Frame

354940–1 and Die Assembly 790163–[ ].

The tool assembly is used to crimp the contacts, and

the internal and external strain reliefs of the modular

plugs listed in Figure 1.

Read these instructions thoroughly before using the

hand tool assembly.

Dimensions in this instruction sheet are in

millimeters. Figures are not drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 8, REVISION SUMMARY.

NOTE

408-8738

PRO-CRIMPER III Hand Tool Assembly 1976319-1 with Die Assembly 1976320-1

Rev

f4 Tyc Electr nics C rp rati n

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.

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 ASSEMBL

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 moving jaw of the tool

frame. Align the holes with the associated holes in

the tool frame. Orient the right housing guide as

shown, and mount it onto the tool frame using the

long retaining pins. Insert the long retaining screw

through the hole in the right housing guide. Tighten

the screw.

4. Refer to Figure 2. Orient the left housing guide

as shown, and secure it onto the tool frame using

the nut. Tighten the nut.

5. Carefully close the tool handles, making sure

that the parts align properly.

6. To disassemble, close the tool handles until the

ratchet releases. Remove the nut, screws, housing

guides, retaining pins, housing support, and

insulation stuffer out of the tool frame jaws.

4. CRIMPING PROCEDURE

Before proceeding, refer to the applicable Application

Specification: 114–22008 (Category 5e EMT) or

114–13035 and 114–93006 (Category 6 shielded),

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 full

bottomed onto the bod . With some cables

containing

shielded twisted pairs

, this is

especiall 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

Insulati n

Stuffer

Right H using

Guide

Sh rt Retaining

Screw

L ng Retaining

Screw

Sh rt Retaining

Pin (2 Places)

L ng Retaining

Pin (2 Places)

H using

Supp rt

Nut

Left H using

Guide

T l Frame

Wire Stuffer (Ref)

S cket Head Cap Screw

(Retains Wire Stuffer,

Ref)

CAUTION

408-8738

PRO-CRIMPER III Hand Tool Assembly 1976319-1 with Die Assembly 1976320-1

of 4Rev

Tyco E ectronics Corporation

Figure 3

Modu ar P ug Bottomed

in Crimping Chamber

Housing

Support

Insu ation

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 lug.

For ro er alignment, make sure to a ly forward

ressure 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.

Crim Height Gage 904170-1 is available to be

used as a quick verification of acce table crim

height as shown in Figure 4. Refer to 408-4389

for instructions on using the gage.

Figure 4

Crimp Height

Gage (Ref)

Modu ar P ug

(Ref)

Checking Crimp Height

5. ADJUSTMENTS

5.1. Rat het 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

Whee

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

408-8738

PRO-CRIMPER III Hand Tool Assembly 1976319-1 with Die Assembly 1976320-1

Rev

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 Maintenan e

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. Periodi Inspe tion

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 Inspe tion

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, 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:

Added modular plug part numbers

Corrected modular plug part number in

Figure 1

Changed hand tool frame part number

Added document references to Section 4

Replaced Section 5 with Step 4 of Section 4

Removed Section 9

NOTE

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