PRO-CRIMPER* III Hand Crimping Tool Assembly with Die Assembly

Transcription

1 PRO-CRIMPER* III Hand Crmpng Tool Assembly wth Assembly Instructon Sheet APR 11 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended-use, producton operatons s avalable. Locator Assembly (Suppled wth Assembly) Assembly Statonary Jaw Pvot Pn Back of Tool Frame (Wre Sde) ORIGINAL INSTRUCTIONS Movng Jaw Ratchet Retanng Screw (2 Places) Ratchet Adjustment Wheel The PRO-CRIMPER III Hand Crmpng Tool s a Commercal grade tool and s desgned prmarly for feld nstallaton, repar, mantenance work, or prototypng n ndustral, commercal, or nsttutonal applcatons. Product crmped wth ths tool wll meet the crmp heght requrement for hand tools n the approprate Applcaton Specfcaton (114-seres), but may not comply wth other feature parameters of the specfcaton. TE Connectvty offers a varety of tools to satsfy your performance requrements. For addtonal nformaton, contact the Toolng Assstance Center at PRO-CRIMPER III Hand Tool Frame ( ) Statonary Handle Movng Handle DIE ASSEMBLY LOCATOR ASSEMBLY PRODUCT FAMILY SIZE RANGE (AWG) WIRE INSULATION DIAMETER (mm [n.]) STRIP LENGTH (mm [n.]) AMPLIMITE* HD Crmp-Snap Contacts [ ] [ ] Fgure 1 1. INTRODUCTION PRO-CRIMPER III Hand Tool Assembly conssts of PRO-CRIMPER III Hand Tool Frame and Assembly The tool assembly s used to crmp the contacts gven n Fgure 1, Read these nstructons thoroughly before usng the tool assembly. Dmensons n ths nstructon sheet are n metrc unts [wth U.S. customary unts n brackets]. Fgures are not drawn to scale. For addtonal nformaton on the hand tool frame, refer to Reasons for ressue of ths nstructon sheet are provded n Secton 9, REVISION SUMMARY. 2. DESCRIPTION (See Fgure 1) The tool consst of a statonary jaw and handle, a movng jaw and handle, and an adjustable ratchet that ensures full crmpng. The tool features a ratchet adjustment wheel for adjustng the crmp heght. A locator assembly s attached to the tool frame and conssts of a locator, sprng retaner, and contact support. The contact support prevents the contact from bendng durng crmpng. A nut used on the long de retanng screw holds the locator assembly n place. The de assembly conssts of two anvl des (wre and nsulaton) and two crmper des (wre and nsulaton) Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER PRODUCT INFORMATION Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 5 LOC B

2 Nut Locator Assembly Tool Jaws Locator Wre Crmper Retanng Pn (4 Places) Chamfer Long Retanng Screw Offset Wre Anvl Insulaton Crmper Chamfer Insulaton Anvl Short Retanng Screw Fgure 2 When closed, the des form two crmpng chambers. Each de s held n the tool frame by a retanng screw and two retanng pns. 3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY AND LOCATOR ASSEMBLY 1. Close the tool handles untl the ratchet releases, then allow the handles to open fully. 2. Remove the two de retanng screws from the tool jaws. 3. Slde the wre anvl and nsulaton anvl des onto the movng jaw so that the chamfers and marked surfaces face outward as shown n Fgure 2, then nsert the two de retanng pns through the holes n the movng jaw and nto the holes n the des. 4. Thread, but do not tghten, the short de retanng screws through the holes of the movng jaw and nto the holes n both anvl des. 5. Slde the wre crmper and nsulaton crmper des onto the statonary jaw so that the chamfers and marked surfaces face outward as shown n Fgure 2, then nsert the two de retanng pns through the holes n the statonary jaw and nto the holes n the des. 6. Thread, but do not tghten, the long de retanng screws through the holes of the movng jaw and nto the holes n both crmper des. 7. Carefully close the tool handles, makng sure that the des algn properly. Contnue closng the handles untl the ratchet has engaged suffcently to hold the des n place. 8. Tghten the de retanng screws usng the approprate screwdrver. 9. Place the locator assembly over the end of the long de retanng screw, and poston the locator assembly aganst the sde of the tool jaw. 10. Place the nut onto the end of the long de retanng screw, and tghten the nut enough to hold the locator assembly n place, whle stll allowng the locator to slde up and down. 11. To dsassemble, close the tool handles untl the ratchet releases. Remove the nut, locator assembly, the two de retanng screws, and four de retanng pns, then, slde the des out of the tool jaws. 4. CRIMPING PROCEDURE The tool frame s provded wth a crmp adjustment feature. Intally, the crmp heght should be verfed accordng to Secton 6, CRIMP HEIGHT INSPECTION, and f necessary, adjusted accordng to Secton 7, CRIMP HEIGHT ADJUSTMENT before usng the tool. Refer to Fgure 1, and select wre of the specfed sze and nsulaton dameter. Strp the wre to the dmenson gven n Fgure 1, takng care not to nck or cut wre strands. Then proceed as follows: 1. Hold the tool so that the back (wre sde) faces you. Close the tool handles untl the ratchet releases, then allow the handles to open FULLY. 2. Insert the contact (nsulaton barrel frst) nto the front of the approprate crmpng chamber (refer to the markngs on the de). 3. Poston the contact so that the matng end s on the locator sde of the tool frame and the open U of the wre barrel and nsulaton barrel faces the top of 2 of 5

3 Contact Support Adjustment Screw for Contact Support Back of Tool Frame (Wre Sde) Crmpng Chamber Wre Strp Length Wre Locator n Wre Stop Slot of Contact Wre Inserted to Wre Stop Fgure 3 the tool frame. Place the contact up nto the crmpng chamber so that the locator drops nto the slot n the contact. Refer to Fgure 3. Butt the front end of the wre barrel aganst the locator. CAUTION! Make sure that both sdes of the nsulaton barrel are started evenly nto the crmpng chamber. DO NOT attempt to crmp an mproperly postoned contact. 4. Hold the contact n poston, and close the tool handles untl the ratchet engages suffcently to hold the contact n poston. DO NOT deform the nsulaton barrel or wre barrel. 5. Insert the strpped wre nto contact nsulaton barrel and wre barrel untl t s butted aganst the wre stop as shown n Fgure Holdng the wre n place, close the tool handles untl the ratchet releases. 7. Allow the tool handles to open FULLY, and remove the crmped contact. The crmped contact may stck n the crmpng area; however the contact can be removed by pushng downward on the top of the locator (see Fgure 3). 8. Check the contact crmp heght, and f necessary, adjust the crmp heght CAUTION! 5. ADJUSTMENTS DO NOT use defectve or damaged products Contact Support The contact support s preset pror to shpment, but mnor adjustment may be necessary f the contact s bendng durng crmpng. Proceed as follows: 1. Make a sample crmp and determne f the contact s bendng (upward or downward). 2. Loosen the screw that holds the contact support onto the locator assembly. 3. Place a contact wth a wre nto the proper crmpng chamber, and close the tool handles untl the ratchet reaches the sxth clck or untl the contact support touches the contact. The ratchet has detents that create audble clcks as the tool handles are closed. 4. Slghtly loosen the nut that holds the locator assembly onto the tool frame. 5. Move the contact support as requred to elmnate the bendng of the contact. 6. Tghten the nut, then close the handles untl the ratchet releases. 7. Remove and nspect the contact. Make another sample crmp. If the contact s straght, tghten the contact support screw. If the contact s stll beng bent durng crmpng, repeat the adjustment procedure Ratchet Adjustment The tool ratchet mechansm features an adjustment wheel wth numbered settngs. The adjustment wheel controls the amount of handle pressure exerted on the jaws durng crmpng. If the crmp s not acceptable, adjust the ratchet as follows: 1. Remove the lockscrew from the ratchet adjustment wheel. Refer to Fgure Usng a screwdrver, adjust the ratchet wheel from the front of the tool. 3 of 5

4 3. Observe the ratchet adjustment wheel. If a tghter crmp s requred, rotate the adjustment wheel counterclockwse to a hgher-numbered settng. If a looser crmp s requred, rotate the adjustment wheel clockwse to a lower-numbered settng. Poston Pont on Center of Wre Barrel Opposte Seam A (See Table) Screwdrver Ratchet Adjustment Wheel Lockscrew Fgure 4 4. Re-nstall the lockscrew. 5. Make a sample crmp. If the crmp s acceptable, the adjustment settng s correct. If the crmp s unacceptable, contnue to adjust the ratchet, and agan measure a sample crmp. 6. CRIMP HEIGHT INSPECTION Crmp heght nspecton s performed through the use of a mcrometer wth a modfed anvl, commonly referred to as a crmp heght comparator. TE does not market crmp heght comparators. Refer to Instructon Sheet for detaled nformaton on obtanng and usng a crmp heght comparator. Proceed as follows: 1. Refer to Fgure 5, and select a maxmum sze wre for each crmpng chamber. 2. Crmp the contacts accordng to Secton Usng a crmp heght comparator, measure the wre barrel crmp heght as shown n Fgure 4. If the crmp heght conforms to the dmenson, the tool assembly s consdered dmensonally correct. If not, the tool frame must be adjusted. Refer to Paragraph 5.2, Crmp Heght Adjustment. 7. MAINTENANCE AND INSPECTION 7.1. Mantenance 1. Ensure that the tool frame and des are clean by wpng them wth a clean, soft cloth. Remove any debrs wth a clean, soft brush. Do not use objects that could damage any components. 2. When not n use, keep tool handles closed to prevent objects from becomng lodged n the des, and store n a clean, dry area. CRIMPING CHAMBER MARKING Fgure 5 3. Remove all lubrcaton and accumulated flm from the des by mmersng the des n a sutable commercal degreaser Vsual Inspecton 1. Inspecton of the tool and des should be made on a regular bass to ensure that they have not become worn or damaged. 2. Make sure that the proper de retanng screws are properly secured. 3. Inspect the crmpng chambers of the de assembly for flattened, chpped, worn, or broken areas. If damage or abnormal wear s evdent, the des must be replaced. Refer to Secton 7, REPLACEMENT AND REPAIR. 8. REPLACEMENT AND REPAIR Avalable separately, Repar Kt ncludes a replacement nut and a varety of pns, rngs, screws, and sprngs. If the des are damaged or worn excessvely, they must be replaced. Order the repar kt, tool assembly, and de assembly through your representatve, or call , or send a facsmle of your purchase order to , or wrte to: CUSTOMER SERVICE ( ) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA REVISION SUMMARY MAXIMUM WIRE SIZE (AWG) DIMENSION A CRIMP HEIGHT (mm [n.]) ±0.05 [.027±.002] ±0.05 [.031±.002] Revsons to ths nstructon sheet nclude: Updated document to corporate requrements New logo 4 of 5

5 Toolng Compatble wth Assembly PRO-CRIMPER III Hand Tool Frame (Instructon Sheet ) SDE-SA Hand Tool (Instructon Sheet ) SDE Bench Termnator (Customer Manual ) 626 Adapter (Instructon Sheet ) Closed Head Assembly Wth Pn s or Shoulder s (Instructon Sheet ) C -Head Assembly Wth Shoulder s Only (Instructon Sheet ) Electro-Hydraulc (BT 3500 Battery-Hydraulc) Hand Tool Kts [ ] (Customer Manual ) 5 of 5