318450-1

Instruction Sheet PRO-CRIMPER* III Hand Crimping 408-4218 Tool Assembly 318450-1 with D ie Assembly 318450-2 01 MAY 09 Rev B 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. Stationary Jaw Die Assembly 318450-2 Back of Tool (Wire Side) PRO-CRIMPER III Hand Crimping Tool Frame 354940-1 (408-9930) Moving Jaw Ratchet Adjustment Wheel Stationary The PRO-CRIMPER III Hand Crimping Tool is a Commercial" grade tool and Handle 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 Moving tools to satisfy your performance requirements. For additional information, Handle contact the Tooling Assistance Center at 1-800-722-1111. Figure 1 1. INTRODUCTION NOTE Dimensions on this sheet are in millimeters [with inches in brackets]. Figures are not drawn PRO–CRIMPER III Hand Crimping Tool Assembly 318450–1 consists of Die Assembly 318450–2 and PRO–CRIMPER III Hand Crimping Tool Frame 354940–1. The hand tool assembly is used to crimp COAXICON* 50–Ohm RF Series BNC and TNC Commercial Connectors 227079–[ ], 414168–[ ], 414171–3, and 414173–[ ] onto various sizes of RG/U cable. For connector assembly and cable stripping procedures, refer to the instructions packaged with the connector. For additional information on the hand tool frame, refer to Instruction Sheet 408–9930. Read these instructions thoroughly before using the hand tool assembly. E 2009 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved i to scale. 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. TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 5 LOC B 408-4218 PRO-CRIMPER III Hand Crimping Tool Assembly 318450-1 Insulation Wire Indenter Indenter Die Retaining Pins Die Retaining Screws Wire Anvil Ferrule Crimping Insulation Chamber Anvil Center Contact Crimping Chamber Figure 2 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 and insulation anvil so that their chamfered sides and their marked surfaces face outward, when mounted in the moving jaw of the tool frame. the anvils and indenters 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 anvils and indenters out of the tool jaws. 4. CRIMPING PROCEDURE NOTE 3. Insert the two die retaining pins. feature. Initially, the crimp height should be 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. i verified as specified in Figure 5. Refer to Section 5, INSPECTION, and Section 6, SHUT HEIGHT ADJUSTMENT, to verify crimp height 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 described in 4.1, and 4.2. 4.1. Center Contact (Figure 3) 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 2 of 5 This tool is provided with a crimp adjustment 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. Tyco Electronics Corporation Rev B 408-4218 PRO-CRIMPER III Hand Crimping Tool Assembly 318450-1 Center Contact Crimp 3. Place the ferrule in the ferrule crimping chamber on the anvil die so that the shoulder of the connector body is against the edge of the die. 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. Center Contact CAUTION Flange Against Edge of Die Damaged contacts must not be used. If a contact is damaged, it must be replaced with a new one. ! 5. INSPECTION Anvil Die 5.1. Visual Inspection Stripped Cable Figure 3 3. Allow the handles to open fully, and remove the crimped center contact from the die assembly. 4.2. Ferrule (Figure 4) 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. Gaging the Crimping Chamber This inspection requires the use of a plug gage conforming to the diameters in Figure 5. Tyco Electronics does not manufacture or market these gages. To gage the crimping chamber, proceed as follows: 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. 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. Ferrule Crimp Cross-Sectional View Ferrule Anvil Die Anvil Die Connector Shoulder Against Edge of Die Figure 4 Rev B Tyco Electronics Corporation 3 of 5 408-4218 PRO-CRIMPER III Hand Crimping Tool Assembly 318450-1 correct, and should be lubricated with a THIN coat of any good SAE 20 motor oil. If not, the dies must be replaced before returning the hand tool and die assembly to service (see Section 8, DIE REPLACEMENT). 2. Align the GO element with the crimping chamber. Push the element straight into the crimping chamber without using force. The GO element must pass completely through the crimping chamber. For additional information regarding the use of a plug gage, refer to Instruction Sheet 408–7424. 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. 6. RATCHET ADJUSTMENT (Figure 6) 4. Repeat Steps 2 and 3 for each crimping chamber listed in Figure 5. NOTE Insert the gage element for the insulation ferrule The frame assembly ratchet mechanism features an adjustment wheel with numbered settings. If the dies do not bottom, adjust the ratchet as follows: section into the back of the crimping chamber. i 1. Remove the lockscrew from the ratchet adjustment wheel. The GO element for this section will not pass completely through the crimping chamber. 2. With a screwdriver, adjust the ratchet wheel from the opposite side of the frame. Suggested Plug Gage for Center Contact Crimping Chamber GO NO-GO DIA DIA 3. Observe the ratchet adjustment wheel. If the dies do not bottom, rotate the adjustment wheel COUNTERCLOCKWISE to a higher–numbered setting. 4. Replace the lockscrew. 7. MAINTENANCE GAGE ELEMENT DIAMETERS GO NO-GO 1.029-1.036 [.0405-.0408] 1.181-1.189 [.0465-.0468] Suggested Plug Gage for Ferrule Crimping Chamber GO DIA 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. For tool repair service, please contact a Tyco Electronics Representative at 1–800–526–5136. W NO-GO DIA Screwdriver R CRIMP SECTION GAGE ELEMENT DIAMETERS GO NO-GO RADIUS (Max) R" WIDTH (Max) W" 4.191-4.199 4.442-4.445 2.03 4.06 [.1650-.1653] [.1749-.1750] [.080] [.160] Insulation 2.413-2.421 2.868-2.870 1.14 2.29 Ferrule [.0950-.0953] [.1129-.1130] [.045] [.090] Ferrule Ratchet Adjustment Wheel Figure 5 Lockscrew (Typ) If the crimping chambers conform to the gage inspection, the dies are considered dimensionally 4 of 5 Tyco Electronics Corporation Figure 6 Rev B 408-4218 PRO-CRIMPER III Hand Crimping Tool Assembly 318450-1 8. REPLACEMENT CUSTOMER SERVICE (38–35) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105–3608 Customer–replaceable parts and dies are shown in Figure 7. Spare parts or the die assembly should be stocked and controlled to prevent lost time when die replacement is necessary. 9. REVISION SUMMARY 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. Since the previous release of this instruction sheet, the following changes were made: S The TE logo was applied; S PRO–CRIMPER II became PROCRIMPER III; S Format was updated to current corporate requirements 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: 1 3 2.64 +0.20 [.104 +.008] 1.04-1.17 [.041-.046] 47.62 [1.88] 4 4.32 +0.10 [.170 +.004] 2 5 11.63 [.458] Weight: 227 g [8 oz] CUSTOMER-REPLACEABLE PARTS DESCRIPTION QTY PER ASSEMBLY ITEM PART NUMBER 1 318432-1 INDENTER, Wire 1 2 318430-1 ANVIL, Wire 1 3 318431-1 INDENTER, Insulation 1 4 318429-1 ANVIL, Insulation 1 5 679231-1 PIN, Die Retaining 4 Figure 7 Rev B Tyco Electronics Corporation 5 of 5