Tyco Electronics PRO CRIMPER III User manual

Instruction Sheet

PRO-CRIMPER* III Hand Crimping

Tool Assembly 224933-1 408-4160

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

11 MAY 09 Rev A

with Die Assembly 224933-2

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduse ofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

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

Stationary Jaw

Back of Tool

(Wire Side)

Pivot Pin

PRO-CRIMPER III Hand

Crimping Tool Frame

354940-1 (408-9930)

Stationary

Handle

Moving Handle

Locator

Assembly

(Supplied with

Die Assembly)

Front of Tool

(Locator Side)

Die

Assembly

Moving Jaw

Ratchet

Adjustment

Wheel

PRO-CRIMPER III Hand Crimping 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

series 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.

Connector

Cable

Die Assembly

Locator Assembly

{

Connector

Family

}

Size

(A G) Insulation

Diameter Shield

Type

I FOPORT*

3.43 to 3.81 mm

[.135 to .150 in.] Small

224933-2 58515-1 Series III

Shield Kit 28-32 5.72 x 3.68 mm

[.225 x .145 in.]

OVAL Large

{

Supplied with die assembly. Also available separately.

}

Contact the Tooling Assistance Center or Product Information Center (below) for specific

shield part numbers.

Figure 1

1. INTRODUCTION

PRO–CRIMPER III Hand Crimping Tool

Assembly 224933–1 consists of Die Assembly

224933–2 and PRO–CRIMPER III Hand Crimping

Tool Frame 354940–1. The die assembly consists of

crimping dies and a locator assembly.

Read these instructions thoroughly before crimping.

Dimensions on this instruction sheet are in

millimeters [with inch equivalents provided in

brackets]. Figures and illustrations are for

identification only and are not drawn to scale.

NOTE

408-4160

PRO-CRIMPER III H nd Crimping Tool Assembly 224933-1

Rev

f4 Tyc Electr nics C rp rati n

Figure 2

Nut

L cat r

Insulati n

Crimper

Chamfer

Insulati n

Anvil

Die Retaining Screws

Die Retaining

Pins

T l Frame

L cat r

Assembly

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 an

adjustable ratchet that ensures full contact crimping.

The tool frame holds a die assembly with two

crimping sections.

The die assembly features an insulation anvil and an

insulation crimper.

Attached to the outside of the frame is a locator

assembly, which contains a locator, a spring retainer,

and a shield support.

Die retaining pins and die retaining screws are used

to position and secure the dies in the tool frame. A

nut is used on the upper die retaining screw to hold

the locator assembly in place.

3. INSTALLATION AND REMOVAL OF DIE SET AND

LOCATOR ASSEMBLY

(Figure 2)

1. Open the tool handles and remove the two die

retaining screws from the tool jaws.

2. Place the insulation anvil 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 short die retaining screw through the

jaw and anvil, and tighten the screw just enough to

hold the anvil in place. Do

not

tighten the screw

completely at this time.

5. Place the insulation crimper so that the

chamfered side faces outward, when mounted in

the stationary jaw of the tool frame.

6. Insert the two die retaining pins.

7. Insert the long die retaining screw through the

jaw and through the crimper 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 crimper align properly. Continue

closing the tool handles until the ratchet in the tool

frame has engaged sufficiently to hold the anvil

and crimper in place, then tighten both die retaining

screws.

9. Place the locator assembly over the end of the

long screw, and position the locator assembly

against the side of the tool jaw.

10. Place the nut onto the end of the long screw

and tighten the nut enough to hold the locator

assembly in place, while still allowing the locator to

slide up and down.

11. To disassemble, close the tool handles until the

ratchet releases, remove the nut, the locator

assembly, the two die retaining screws, and the

four die retaining pins, and slide the anvil and

crimper out of the tool jaws.

4. SHIELD SUPPORT ADJUSTMENT

(Figure 3)

The shield support is preset prior to shipment, but

minor adjustment may be necessary.

1. Make a sample crimp and determine if the

shield is straight, bending upward, or bending

downward.

NOTE

408-4160

PRO-CRIMPER III Hand Crimpin Tool Assembly 224933-1

of 4Rev

Tyco Electronic Corporation

Figure 3

Adju tment

Screw for

Shield

Support

Shield Support Locator

Back of Tool

(Wire Side)

Locator

Butted

Again t

In ulation

Barrel

Shield

(Typ)

Crimper

In ulation

Barrel

Anvil

Cable

Shield Cable

2. If adjustment is required, loosen the screw that

holds the shield support onto the locator assembly.

The ratchet has detents that create audible clicks

as the tool handles are closed.

3. Place a shield with wire into the proper nest and

close the tool handles until the ratchet reaches the

sixth click, or until the shield support touches the

shield.

4. Slightly loosen the nut that holds the locator

assembly onto the tool frame.

5. Move the shield support as required to eliminate

the bending of the shield.

6. Tighten the nut and close the handles until the

ratchet releases.

7. Remove and inspect the shield.

8. Make another sample crimp. If the shield is

straight, tighten the shield support screw. If the

shield is still being bent during crimping, repeat the

adjustment procedure.

5. CRIMPING PROCEDURE

This tool is provided with a crimp adjustment

eature. Initially, the crimp height should be

veri ied as speci ied in Figure 4. Re er to

Section 6, CRIMP HEIGHT INSPECTION, and

Section 7, CRIMP HEIGHT ADJUSTMENT, to

veri y crimp height be ore using the tool to crimp

desired shields and wire sizes.

Prepare the cable, connector, and shields in

accordance with the instructions contained in the

applicable Application Specification. Ensure that cable

drain wire(s) is positioned between the cable

insulation jacket and the insulation crimping barrel of

the lower shield. Refer to the table in Figure 1 to

determine if the shield type (small or large) is

compatible with the cable size and insulation

diameter. Then identify the appropriate crimp section

according to the wire size markings on the tool. Refer

to Figure 3 and proceed as follows:

1. Hold the tool so that the back (wire side) is

facing you. Squeeze tool handles together and

allow them to open fully.

2. Holding the shield by the mating end, insert the

shield — insulation barrel first — through the front

of the tool and into the appropriate crimp section.

3. Position the shield so that the mating end of the

shield is on the locator side of the tool, and so that

the open “U” of the insulation barrel faces the top

of the tool. Place the shield up into the nest so that

the movable locator butts against the front end of

the insulation barrel. Refer to Figure 3.

Make sure that both sides o the insulation barrel

are started evenly into the crimping section. Do

NOT attempt to crimp an improperly positioned

shield.

4. Hold the shield in position and squeeze the tool

handles together until ratchet releases.

5. Allow tool handles to open and remove crimped

shield.

The crimped shield may stick in the crimping

area, but the shield can be easily removed by

pushing downward on the top o the locator (see

Figure 3).

6. Check the shield’s crimp height as described in

Section 6, CRIMP HEIGHT INSPECTION. If

necessary, adjust the crimp height as described in

Section 7, CRIMP HEIGHT ADJUSTMENT.

6. CRIMP HEIGHT INSPECTION

This inspection requires the use of a micrometer with

a modified anvil.

NOTE

CAUTION

NOTE

408-4160

PRO-CRIMPER III Hand Crimping Tool Assembly 224933-1

Rev

of 4 Tyco Electronics Corporation

Tyco Electronics does not manufacture or market

these gages. However TE recommends the

modified micrometer (Crim Height Com arator

RS-1019-5LP) or the digital Mitutoyo

micrometer.

Proceed as follows:

1. Refer to Figure 4 and select a cable (maximum

size) for each crimp section listed.

2. Refer to Section 5, CRIMPING PROCEDURE,

and crimp the shield(s) accordingly.

3. Using a crimp height comparator, measure the

insulation barrel crimp height as shown in Figure 4.

If the crimp height conforms to that shown in the

table, the tool is considered dimensionally correct.

If not, the tool must be adjusted. Refer to Section

7, CRIMP HEIGHT ADJUSTMENT.

Position

Point on

Center of

Insulation Barrel

Opposite

Seam

Modified Anvil

A"

Insulation

Diameter

Crimp Section

(Insulation Size

Marking)

Crimp Height

Dim. (A") and

Tolerance (+)

3.43 to 3.81

[0.135 to 0.150 S2.64 +.05

[0.104 +.002

5.72 x 3.68

[0.225 x 0.145

OVAL L3.25 +.05

[0.128 +.002

Figure 4

7. RATCHET (Crimp Height) ADJ STMENT

(Figure 5)

1. Remove the lockscrew from the ratchet

adjustment wheel.

2. With a screwdriver, adjust the ratchet wheel

from the locator side 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.

Figure 5

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew

(Typ)

4. Replace the lockscrew.

5. Make a sample crimp and measure the crimp

height. If the dimension is acceptable, replace and

secure the lockscrew. If the dimension is

unacceptable, continue to adjust the ratchet, and

again measure a sample crimp.

8. 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.

9. VIS AL INSPECTION

The crimping dies should be inspected on a regular

basis to ensure that they have not become worn or

damaged. Inspect the crimp sections for flattened,

chipped, worn, or broken areas. If damage or

abnormal wear is evident, the tool must be replaced.

See Section 10, REPLACEMENT.

10. REPLACEMENT

Customer–replaceable parts are shown in Figure 1.

Available separately, PRO–CRIMPER III Hand

Crimping Tool Repair Kit 679221–1 includes a

replacement nut and 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

1–717–986–7605, or write to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS

PO BOX 3608

HARRISBURG PA 17105–3608

11.REVISION S MMARY

Since the previous release of this instruction sheet:

The TE logo has been applied; and

The format has been updated.

NOTE

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