Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet

PRO-CRIMPER* III Hand

Tool Assembly 224928-1 408-4167

L C B

of 4

2008 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

24 JAN 08 Rev A

with Die Assembly 224928-2

PROPER SE G IDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

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

Figure 1

}

Contact the Tooling Assistance Center

(see below) for specific connector part numbers.

The PR -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.

Ratchet

Adjustment Wheel

PR -CRIMPER III

Hand Tool Frame

354940-1

Stationary

Handle

Moving

Handle

Pivot

Back of Tool

Stationary

Jaw

Die Assembly

224928-2

Moving Jaw

DIE ASSEMBLY

PART N MBER CONNECTOR

FAMILY

}

TYPE

CABLE

INS L DIA

(mm [in.])

224928-2 Modular Plug Connectors

(External Strain Relief Application) Stranded or Solid,

Unshielded or Shielded Round Jacket 4.70-5.46

[.185-.215]

1. INTROD CTION

PRO–CRIMPER III Hand Tool Assembly 224928–1

consists of Die Assembly 224928–2 and

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

die assembly consists of two crimping dies. Read

these instructions thoroughly before crimping any

connectors.

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.

Reason for revision is provided in Section 9,

REVISION SUMMARY.

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 an

adjustable ratchet that ensures external strain relief

crimping. The tool frame holds a die assembly with a

seating chamber and two crimping chambers.

The die assembly features an indenter die and an

anvil die.

Die retaining pins and die retaining screws are used

to position and secure the dies in the tool frame.

NOTE

408-4167

PRO-CRIMPER III Hand Tool Assembly 224928-1 with Die Assembly 224928-2

Rev

of 4 Tyco Elect onics Co po ation

Figure 2

Anvil

Die

Chamfe

Die Retaining

Sc ews

Die Retaining

Pins

Tool F ame

Indente

Die

Wi e Insulation

Diamete Ma kings

3. INSTALLATION AND REMOVAL OF

DIE ASSEMBL

(Figu e 2)

1. Open the tool handles and remove the two die

retaining screws from the tool jaws.

2. Place the anvil die so that the chamfered side

faces outward when mounted in the moving jaw of

the tool frame.

3. Insert the two die retaining pins.

4. Insert the die retaining screw through the jaw

and through the anvil die, and tighten the screw

just enough to hold the die in place. Do

not

tighten

the screw completely at this time.

5. Observe the wire insulation diameter markings

on the indenter die. Place the indenter die so that

the crimping chamber to be used is facing outward

when mounted in the stationary jaw of the tool

frame.

6. Insert the two die retaining pins.

7. Insert the die retaining screw through the jaw

and the indenter die, and tighten the screw just

enough to hold the die in place. Do

not

tighten the

screw completely at this time.

8. Carefully close the tool handles, making sure

that the anvil and indenter align properly. Continue

closing the tool handles until the ratchet in the tool

frame has engaged sufficiently to hold the anvil

and indenter in place, then tighten both die

retaining screws.

9. 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 anvil and indenter out of the tool jaws.

4. CRIMPING PROCEDURE

Assemble the modular plug connector according to

Application Specification 114–6016. Insert the

external strain relief into the modular plug as shown in

Figure 3, Detail A, and proceed as follows:

1. Squeeze tool handles together and allow them

to open fully.

2. Position the modular plug assembly in the

seating chamber on the anvil die as shown in

Figure 3, Detail B. Make sure that the external

strain relief faces the indenter die and that the

support barrel does not enter the seating chamber.

3. Hold the modular plug assembly in position and

squeeze the tool handles together until ratchet

releases. Allow tool handles to open and remove

the modular jack assembly.

4. Position the modular plug assembly in the

crimping chamber on the anvil die so that the

opening in the external strain relief support barrel

faces the indenter die. Make sure the back of the

modular plug butts against the edge of the die. See

Figure 3, Detail C.

408-4167

PRO-CRIMPER III Hand Tool Asse bly 224928-1 with Die Asse bly 224928-2

of 4Rev

Tyco Electronics Cor oration

Make sure that both sides of the support barrel

are started evenly into the crimping chamber. Do

NOT attempt to crimp an improperly positioned

modular plug assembly.

5. Holding the modular plug assembly in place,

squeeze tool handles together until ratchet

releases. Allow tool handles to open and remove

crimped modular plug assembly.

6. Check the external strain relief for a proper

crimp as shown in Figure 4. If necessary, adjust

the crimp height as described in Section 5, CRIMP

HEIGHT ADJUSTMENT.

Figure 3

Insert External

Strain Relief into

Modular Plug

Su ort Barrel in Crim ing

Chamber on Anvil Die with

O ening in Su ort Barrel

Facing Indenter Die

Su ort

Barrel

External Strain Relief

Faces Indenter Die

Back of Modular

Plug Butts Against

Edge of Die

Detail A

Detail B

Detail C

Figure 4

Acceptable Unacceptable

External Strain Relief Must Be

Seated Flat Against Modular Plug

Su ort Barrel Must

Be Evenly Crim ed

and Firm Around Cable

Su ort Barrel

Crim Too Loose

Su ort Barrel Crim Uneven

and Cuts into Cable

CAUTION

408-4167

PRO-CRIMPER III H nd Tool Assembly 224928-1 with Die Assembly 224928-2

Rev

of 4 Tyco Electron cs Corporat on

5. CRIMP NEST

The crimp nest may be removed and rotated 180°to

accommodate two sizes of insulation. Dimensions for

these wire insulation sizes are shown in Figure 5.

Figure 5

For 4.70-5.08 mm [.185-.200 in.] Insulation Dia.

For 5.08-5.46 mm [.200-.215 in.] Insulation Dia.

8.43 +0.15

[.332 +.006]

8.43 +0.15

[.332 +.006]

5.33 +0.10

[.210 +.004]

6.10 +0.10

[.240 +.004]

.185-.200

.200-.215

6. CRIMP HEIGHT ADJUSTMENT

(F gure 6)

1. Remove the lockscrew from the ratchet

adjustment wheel.

2. With a screwdriver, adjust the ratchet wheel

from the back 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. Replace the lockscrew.

5. Make a sample crimp and visually check the

crimp height (refer to Figure 4). If the crimp is

acceptable, replace and secure the lockscrew. If

the crimp is unacceptable, continue to adjust the

ratchet, and again measure a sample crimp.

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. VISUAL 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 tool must be

replaced. See Section 9, REPLACEMENT.

Figure 6

Screwdr ver

Ratchet

Adjustment

Wheel

Lockscrew

(Typ)

9. REPLACEMENT

Customer–replaceable parts are shown in Figure 1. If

the dies are damaged or worn excessively, they must

be replaced. 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

P.O. BOX 3608

HARRISBURG, PA 17105–3608

10. REVISION SUMMARY

Updated document to corporate requirements

Added new Section 5, and renumbered

Added new Figure 5 and renumbered

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