Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet

PRO-CRIMPER* III Han Crimping

Tool Assembly 318451-1 with 408-4217

L C B

of 5

2009 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

30 APR 09 Rev B

Die Assembly 318451-2

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

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

The PR -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 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

Crimping Tool Frame

354940-1 (408-9930)

Stationary

Handle

Moving Handle

Stationary

Jaw

Die Assembly

318451-2

Moving

Jaw

Figure 1

Back of Tool

(Wire Side)

1. INTRODUCTION

PRO–CRIMPER III Hand Crimping Tool Assembly

318451–1 consists of Die Assembly 318451–2 and

PRO–CRIMPER III Hand Crimping Tool Frame

354940–1. The hand tool assembly is used to crimp

75–Ohm RF Series BNC Commercial Plug Connector

221185–8 and Bulkhead Jack Connector 221221–5

onto various sizes of RG/U cable.

For connector assembly and cable stripping

procedures, refer to instruction sheet 408–9088 for

the plug connectors and 408–9089 for the jack

connectors. Read these instructions thoroughly

before using the hand tool assembly. This document

supersedes Instruction Sheet 408–9282.

Dimensions on this sheet are in millimeters

[with inches in brackets]. Figures are for

reference only and are not drawn to scal

Reasons for reissue of this instruction sheet are

provided in Section 9, REVISION SUMMARY.

2. DESCRIPTION

(Figures 1 and 2)

The hand tool assembly features a tool frame with a

stationary jaw and handle, a moving jaw, a moving

handle, and an adjustable ratchet that ensures full

connector crimping.

The tool frame holds a die assembly with two

crimping chambers. The die assembly features a wire

anvil, an insulation anvil, a wire indenter, and an

insulation indenter. Die retaining pins and die retaining

screws are used to position and secure the dies in the

tool frame.

NOTE

408-4217

PRO-CRIMPER III H nd Crimping Tool Assembly 318451-1

Rev

of 5 Tyco Elect onics Co po ation

Figure 2

Die Retaining

Sc ews

Die Retaining

Pins

Wi e

Indente

Wi e

Anvil

Insulation

Anvil

Insulation

Indente

Fe ule C imping

Chambe

Cente Contact

C imping Chambe

3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY

(Figu e 2)

1. Open the tool handles and remove the two die

retaining screws from the tool jaws.

2. Place the wire anvil and insulation anvil so that

their chamfered sides and their marked surfaces

face 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 through both anvil dies, and tighten the

screw just enough to hold the dies in place. Do

not

tighten the screw completely at this time.

5. Place the wire indenter and insulation indenter

so that their chamfered sides and their marked

surfaces face 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 both indenter dies, and tighten the

screw just enough to hold the dies in place. Do

not

tighten the screw completely at this time.

8. Carefully close the tool handles, making sure

that the anvils and indenters align properly.

Continue closing the tool handles until the ratchet

in the tool frame has engaged sufficiently to hold

the anvils and indenters in place, then tighten both

die retaining screws.

9. To remove, close the tool handles until the

ratchet releases, remove the two die retaining

screws and the four die retaining pins, and slide

the anvils and indenters out of the tool jaws.

4. CRIMPING PROCEDURE

This tool is provided with a crimp ad ustment

feature. Initially, the crimp height should be

verified as specified in Figures 5 and 6. Refer to

Section 5, INSPECTION, and Section 6, CRIMP

HEIGHT ADJUSTMENT, to verify crimp before

using the tool to crimp desired connectors and

wire sizes

Slide the ferrule onto the cable and strip the cable

according to the dimensions provided in the

instructions packaged with the connector. Take care

not to nick or cut wire strands. Proceed as follows:

4.1. Center Cont ct

(Figu e 3)

1. Slide center contact onto stripped conductor.

Insert center contact assembly into the partially

closed center contact crimping chamber on the

anvil die. Make sure the center contact flange is

against the edge of the die as shown in Figure 3.

2. While holding the cable in place, crimp the

center contact by closing the tool handles until the

ratchet releases.

3. Allow the handles to open fully, and remove the

crimped center contact from the die assembly.

NOTE

408-4217

PRO-CRIMPER III Hand Crimping Tool Ass mbly 318451-1

of 5Rev

T co Electronics Corporation

Figure 3

Center Contact

Flange Against

Edge of Die

Anvil Die

Stripped Cable

Center Contact Crimp

4.2. F rrul

(Figure 4)

1. Flare the cable braid and insert the crimped

center contact into the connector body until the

cable dielectric is against the dielectric inside the

connector body. The flared braid will then fit over

the support sleeve of the connector body.

2. Slide the ferrule forward over the braid until the

ferrule is against the connector body.

3. Place the ferrule in the crimping chamber on the

anvil die so that the shoulder of the connector body

is against the edge of the die. Refer to Figure 4.

4. Holding the assembly in place, close the tool

handles until the ratchet releases.

5. Allow the handles to open fully, and remove the

crimped assembly from the die assembly.

Da aged contacts should not be used. If a

da aged contact is evident, it should be cut fro

the wire and replaced with a new one. Contacts

should not be reter inated.

5. INSPECTION

5.1. Visual Insp ction

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 8, DIE REPLACEMENT.

5.2. P riodic Insp ction

A. C nt r Contact Crimp H ight Insp ction

This inspection requires the use of a micrometer with

a modified anvil as shown in Figure 5.

Tyco Electronics does not anufacture or arket

these gages. However TE reco ends the

odified icro eter (Cri p Height Co parator

RS-1019-5LP).

Proceed as follows to check the crimp height of the

center contact:

1. Select the center contact for the connector.

Figure 4

Anvil Die

Ferrule

Ferrule Crimp

Connector Shoulder

Against Edge of Die

Cross-Sectional

View

Anvil Die

CAUTION

NOTE

408-4217

PRO-CRIMPER III Hand Crimping Tool Assembly 318451-1

Rev

of 5 Tyco Electronics Corporation

Figure 5

1.0287-1.1811

[.0405-.0465]

Position Point

on Center of

ire Barrel

Modified

Anvil

Measuring Center Contact Crimp Height

2. Refer to Section 4, CRIMPING PROCEDURE,

and crimp the center contact accordingly.

3. Using a crimp height comparator, measure the

crimp height as shown in Figure 5. If the crimp

height conforms to that shown, the die assembly is

considered dimensionally correct. If not, return the

dies to Tyco Electronics for evaluation and repair

(refer to Section 8, DIE REPLACEMENT).

B. Gaging the Ferrule Crimping Chamber

This inspection requires the use of a plug gage

conforming to the dimensions in Figure 6. Tyco

Electronics does not manufacture or market these

gages. To gage the ferrule crimping chamber,

proceed as follows:

1. Close the jaws until the dies have bottomed,

then HOLD the frame handles in this position. Do

NOT force the dies beyond initial contact.

NO-GO DIM.GO DIM.

Suggested Plug Gage for

Ferrule Crimping Chamber

CRIMP

ECTION

GAGE ELEMENT

DIMEN ION RADIU

(

Max

)

WIDTH

(

Max

)

ECTION

GO NO-GO

(Max)

R"

(Max)

W"

Ferrule 4.1910-4.1986

[.1650-.1653] 4.4424-4.4450

[.1749-.1750] 2.032

[.080] 4.064

[.160]

Insulation

Ferrule 2.4130-2.4206

[.0950-.0953] 2.8676-2.8702

[.1129-.1130] 1.016

[.040] 2.286

[.090]

Figure 6

2. Align the GO element with the ferrule crimping

chamber. Push the element straight into the

crimping chamber without using force. The GO

element must pass completely through the

crimping chamber.

3. Align the NO–GO element and try to insert it

straight into the same crimping chamber. The

NO–GO element may start entry, but must not

pass completely through.

4. Repeat Steps 2 and 3 for the insulation ferrule

section of the crimping chamber.

Insert the gage element for the insulation ferrule

section into the back of the crimping chamber.

The GO element for this section will not pass

completely through the crimping chamber.

6. CRIMP HEIGHT ADJU TMENT

(Figure 7)

The frame assembly ratchet mechanism features an

adjustment wheel with numbered settings. If the crimp

height 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 opposite side of the frame.

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 measure the crimp

height. If the crimp height is acceptable, secure the

lockscrew. If the dimension is unacceptable,

remove lockscrew and continue to adjust the

ratchet, and again measure a sample crimp.

Figure 7

Screwdriver

Ratchet

Adjustment

heel

Lockscrew

(Typ)

NOTE

408-4217

PRO-CRIMPER III Hand Crimping Tool Assembly 318451-1

of 5Rev

Tyco Electronics Corporation

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

Customer–replaceable parts and dies are shown in

Figure 8. Spare parts or the die assembly should be

stocked and controlled to prevent lost time when die

replacement is necessary.

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.

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

PO BOX 3608

HARRISBURG PA 17105–3608

For customer repair service, contact a Tyco

Electronics Representative at 1–800–526–5136.

9. RE ISION SUMMARY

Since the previous release of this instruction sheet,

the following change were made:

TE logo was applied; and

The format was updated to the current

corporate requirements.

1.04-1.17

[.041-.046]

2.64 +0.20

[.104 +.008]

4.32 +0.10

[.170 +.004]

47.62

[1.88]

11.63

[.458]

Weight:

227 g [8 oz]

One side can go 0.064 [.0025] out of tolerance as long as the average

measurements of oth sides are within dimension s

ecified.

CUSTOMER-REPLACEABLE PARTS FOR DIE ASSEMBLY 318451-2

ITEM PART NUMBER DESCRIPTION QTY PER

ASSEMBLY

1 318432-1 INDENTER, Wire 1

2 318430-1 ANVIL, Wire 1

3 318431-2 INDENTER, Insulation 1

4 318429-2 ANVIL, Insulation 1

5 679231-1 PIN, Die Retaining 4

Figure 8

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