Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO-CRIMPER* III

Hand Tool Assembly 217212-1 408-4145

LOC B

of 4

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

20 MAR 09 Rev D

with Die Assembly 217212-2

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduse ofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

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

The PRO-CRIMPER III Hand 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.

CERTI-CRIMP*

Ratchet

PRO-CRIMPER III Hand Tool

Frame 354940-1

(See Instruction Sheet 408-9930)

Stationary

Handle

Moving

Handle

Back of Tool

(Wire Side)

Stationary

Jaw

Front of Tool

Die Assembly

217212-2

Moving

Jaw

DIE

ASSEMBL

CLOSED-END

SPLICE WIRE SOLID OR STRANDED

WIRE COMBINATION

CRIMPING

CHAMBER PART

NUMBER T PE SIZE RANGE

(AWG) CIRCULAR MIL

AREA RANGE STRIP LENGTH TABLE SHOWN ON

(INSTRUCTION SHEET)

Outer 35115 ECV

EC 22-14 509-5,180 8.76 +0.38 [.345 +.016] (408-1271)

Center 328730 ECV

EC 22-10 3,248-13,100 11.12 +0.38 [.438 +.016] (408-1003)

Inner 35653 EC 22-10 3,248-13,100 11.12 +0.38 [.438 +.016] (408-1021)

Figure 1

1. INTRODUCTION

PRO–CRIMPER III Hand Tool Assembly 217212–1

consists of Die Assembly 217212–2 and

PRO–CRIMPER III Hand Tool Frame 354940–1. The

die assembly consists of two crimping dies. Read

these instructions thoroughly before crimping any

splices.

Dimensions on this sheet are in millimeters [with

inch equivalents provided in brackets]. Figures

and illustrations are for identification only and are

not drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 9, REVISION SUMMARY.

NOTE

408-4145

PRO-CRIMPER III H nd Tool Assembly 217212-1

Rev

of 4 Tyco Elec ronics Corpora ion

Figure 2

Chamfer

Wire Crimper

Die

Wire Anvil

Die

Die Re aining

Screws

Die Re aining

Pins

Tool Frame

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 a

CERTI–CRIMP ratchet that ensures full splice

crimping. The tool frame holds a die assembly with

three crimping chambers.

The die assembly features a wire anvil die and a wire

crimper die. Die retaining pins and die retaining

screws are used to position and secure the dies in the

tool frame.

3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY

(Figure 2)

1. Open the tool handles and remove the two die

retaining screws from the tool jaws.

2. Place the wire anvil die so that the chamfered

side faces outward when mounted in the moving

jaw of the tool frame. Place the wire crimper die so

that the chamfered side faces outward when

mounted in the stationary jaw of the tool frame.

3. Insert two die retaining pins through each jaw

and into each die.

4. Insert the die retaining screws through each jaw

and into each die, and tighten the screws just

enough to hold the dies in place. Do

not

tighten the

screws completely at this time.

5. Carefully close the tool handles, making sure

that the anvil and crimper dies align properly.

Continue closing the tool handles until the ratchet

in the tool frame has engaged sufficiently to hold

the dies in place, then tighten both die retaining

screws.

6. To disassemble, close the tool handles until the

ratchet releases, remove the two die retaining

screws and the four die retaining pins, and slide

the dies out of the tool jaws.

4. CRIMPING PROCEDURE

Initially, the crimping chambers and t l ratchet

sh uld be inspected as specified in Secti n 5,

CRIMP ADJUSTMENT, t verify reliability bef re

using the t l t crimp desired splices and wire

sizes.

Refer to Figure 1 and select wire of the specified size.

Strip the wire to the length indicated in Figure 1,

taking care not to nick or cut wire strands. Select an

applicable splice and identify the appropriate crimping

chamber according to Figure 1. Refer to Figure 3 and

proceed as follows:

1. Squeeze tool handles together and allow them

to open fully.

2. Insert stripped wire into splice wire barrel until

the end of the conductor bottoms against the

splice.

3. Holding the wire, insert the splice—wire barrel

first—into the appropriate crimping chamber. Make

sure the wire barrel is centered in the crimping

chamber.

Make sure that b th sides f the wire barrel are

started evenly int the crimping chamber. D

NOT attempt t crimp an impr perly p siti ned

splice.

NOTE

CAUTION

408-4145

PRO-CRIMPER III Han Tool Assembly 217212-1

of 4Rev

Tyco Elec ronics Corpora ion

4. Holding the splice in place, squeeze tool

handles together until ratchet releases. Allow tool

handles to open and remove crimped splice.

5. Check the splice to ensure that the crimp is

centered on wire barrel and the stripped wires are

fully bottomed in the splice. Refer to Figure 3 for a

properly crimped splice.

Damaged product should not be used. If

damaged product is evident, it should be cut from

the wire and replaced with a new one.

5. CRIMP ADJUSTMENT

5.1. Gaging the Crimping Chamber

This inspection requires the use of a plug gage

conforming to the dimensions shown in Figure 4. Tyco

Electronics does not manufacture or market these

gages. To gage the crimping chamber, proceed as

follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gage.

2. Close the tool handles until it is evident that the

dies have bottomed; HOLD the tool in this position.

Do NOT force the dies beyond initial contact.

3. Align the GO element with the crimping

chamber. Push the element (without forcing it)

straight into the chamber. The GO element must

pass completely through the crimping chamber.

4. Align and try to insert the NO–GO element with

the same crimping chamber. The NO–GO element

may start entry but must not pass completely

through the crimping chamber.

If the crimping chamber conforms to the gage

inspection, the die assembly is considered

dimensionally correct and should be lubricated with a

THIN coat of any good grade SAE 20 motor oil. If not,

the dies or tool frame must be repaired before

returning it to service. See Section 8,

REPLACEMENT AND REPAIR.

For additional information concerning the use of a

plug gage, refer to Instruction Sheet 408–7424.

5.2. CERTI-CRIMP Ratchet

The CERTI–CRIMP ratchet should be checked to

make sure that the ratchet does not release

prematurely allowing the dies to open before they

have fully bottomed. Obtain a 0.025 [.001] shim that

is suitable for checking the clearance between the

bottoming surfaces of the crimping dies.

Proceed as follows:

1. Select a splice and the maximum number of

wires permitted as indicated in the splice wire

combination chart (refer to Figure 1).

2. Position the splice and wire between the

crimping dies, according to Section 4, CRIMPING

PROCEDURE. Holding the splice in place,

squeeze the tool handles together until the

CERTI–CRIMP ratchet releases. Hold the tool

handles in this position, maintaining just enough

pressure to keep the dies closed.

3. Check the clearance between the bottoming

surfaces of the crimping dies. If the clearance is

0.025 [.001] or less, the ratchet is satisfactory. If

clearance exceeds 0.025 [.001], the ratchet is out

of adjustment and must be repaired. See Section

8, REPLACEMENT AND REPAIR.

Figure 3

Back of Tool

Splice wi h

Wire Inser ed Crimp

Cen ered

S ripped Wires Fully

Bo omed in Splice

Note:

Crimp May Be Off Cen er Bu No

Off End of Wire Barrel

Ou er

Crimping

Chamber

Cen er

Crimping

Chamber

Inner

Crimping

Chamber

CAUTION

408-4145

PRO-CRIMPER III H nd Tool Assembly 217212-1

Rev

of 4 Ty o Ele troni s Corporation

Crimping

Chamber

Element NO-GO

Element

GO" gage must pass

ompletely through

rimping surfa e.

NO-GO" gage may enter

partially, but must not pass

ompletely through the length

of the rimping surfa e.

ÉÉ

25.4 [1.00]

Min (Typ)

GO Dim. NO-GO Dim.

Suggested Plug Gage Design

Die Closure

Configuration

CRIMPING GAGE ELEMENT DIMENSIONS

CHAMBER GO NO-GO

Outer 2.438-2.443

[.0960-.0962] 2.540-2.545

[,1000-.1002]

Center 2.946-2.951

[.1160-.1162] 3.048-3.053

[.1200-.1202]

Inner 3.200-3.205

[.1260-.1262] 3.302-3.307

[.1300-.1302]

Figure 4

If the die assembly and tool conform to these

inspection procedures, lubricate it with a THIN coat of

any good SAE 20 motor oil and return it to service.

6. INSPECTION

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 dies must be

replaced. See Section 8, REPLACEMENT AND

REPAIR.

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 AND REPAIR

Customer–replaceable parts are shown in Figure 1.

Available separately, PRO–CRIMPER III Repair Kit

679221–1 includes 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

717–986–7605, or write to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105–3608

9. REVISION SUMMARY

Since the previous release, the Tyco Electronics’ logo

has been changed.

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