Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO- CRIMPER* III Hand 408--10320

LOC B

1of 4

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

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*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1--800--722--1111

PRODUCT INFORMATION 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

01 SEP 09 Rev ACrimping Tool Assembly 1976200- [ ]

PROPER USE GUIDELINES

Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume

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

PRO--CRIMPER III hand crimping 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

Crimping Tool Frame 354940--1

Pivot Pin

Back of Tool

Stationary

Jaw

CABLE

HAND TOOL

ASSEMBLY

DIE

ASSEMBLY

MODULAR

PLUG OUTSIDE

DIAMETER

CONDUCTOR

SIZE (AWG)

CONDUCTOR

INSULATION

DIAMETER (mm)

STRIP

LENGTH

1976200--1 1976200--2

Contact Product

Information or Tooling

Assistance Center

(See Bottom of Page)

5--6 mm

[.197--.236] 26--24 2.03--2.54

[.080--.100]

35.0+5.0

[1.38 +.02]

1976200--3 1976200--4

Contact Product

Information or Tooling

Assistance Center

(See Bottom of Page)

6--7 mm

[.236--.275] 26--24 2.03--2.54

[.080--.100]

35.0+5.0

[1.38 +.02]

Figure 1

1. INTRODUCTION

PRO--CRIMPER III Hand Crimping Tool Assembly

1976200--[ ] consists of PRO--CRIMPER III Hand Tool

Frame 354940--1 and Die Assemblies listed in

Figure 1.

The tool assembly is used to crimp the contacts, and

the internal and external strain reliefs of the Secure

Modular Plugs listed in Figure NO TAG.

Read these instructions thoroughly before using the

hand tool assembly.

Dimensions in this instruction sheet are in

millimeters and [inches in brackets]. Figures and

illustrations are for reference only and are not

drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 8, REVISION SUMMARY.

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.

NOTE

408- 10320

PRO- CRIMPER III Hand Crimping Tool Assembly 1976200- [ ]

Rev A2 of 4 Tyco Electronics Corporation

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 ASSEMBLY

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 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.

4. Carefully close the tool handles, making sure

that the parts align properly.

5. To disassemble, close the tool handles until the

ratchet releases. Remove the screws, 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--13035 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 fully

bottomed onto the body. With some cables

containing shielded twisted pairs,thisis

especially 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

Insulation

Stuffer

Retaining

Screw

Retaining Screw

Retaining Pin

(2 Places)

Retaining Pin

(2 Places)

Housing

Support

Tool Frame

Wire Stuffer

(Ref)

Socket Head Cap

Screw (Retains

Wire Stuffer Ref)

Strain Relief

Depressor

CAUTION

408- 10320

PRO- CRIMPER III Hand Crimping Tool Assembly 1976200- [ ]

3of 4Rev ATyco Electronics Corporation

Figure 3

Modular Plug Bottomed

in Crimping Chamber

Housing

Support

Insulation

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 plug.

For proper alignment, make sure to apply forward

pressure 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.

Crimp Height Gage 904170--1 is to be used as a

quick verification of acceptable crimp height as

shown in Figure 4. Refer to Instruction Sheet

408--4389 for instructions on using the gage.

Figure 4

Crimp Height

Gage (Ref)

Modular Plug

(Ref)

Checking Crimp Height

5. ADJUSTMENTS

5.1. Ratchet 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

Wheel

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- 10320

PRO- CRIMPER III Hand Crimping Tool Assembly 1976200- [ ]

Rev A4 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 Maintenance

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. Periodic Inspection

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 Inspection

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, PRO--CRIMPER III Hand Tool

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:

SInitial release of document

NOTE

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