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8/2/2019 manualalicate

1/4

I n s t r u c t i o n S h e e t

P R O - C R I M P E R I I I H a n d T o o l a n d D i e 7 9 0 1 6 3

4 0 8 - 8 7 3 8

E 2 0 0 4 T y c o E l e c t r o n i c s C o r p o r a t i o n , H a r r i s b u r g , P A

A l l I n t e r n a t i o n a l R i g h t s R e s e r v e d

A M P a n d T y c o a r e t r a d e m a r k s . * T r a d e m a r k

O t h e r p r o d u c t s , l o g o s , a n d c o m p a n y n a m e s u s e d a r e t h e p r o p e r t y o f t h e i r r e s p e c t i v e o w n e r s .

L O C B

1 o f 4

T O O L I N G A S S I S T A N C E C E N T E R 1 - 8 0 0 - 7 2 2 - 1 1 1 1

F A X / P R O D U C T I N F O 1 - 8 0 0 - 5 2 2 - 6 7 5 2

F o r R e g i o n a l C u s t o m e r S e r v i c e , v i s i t o u r w e b s i t e a t

w w w . t y c o e l e c t r o n i c s . c o m

T h i s c o n t r o l l e d d o c u m e n t i s s u b j e c t t o c h a n g e .

F o r l a t e s t r e v i s i o n , c a l l t h e F A X / P R O D U C T I N F O n u m b e r .

0 1 S E P 0 4 R e v O f o r E M T M o d u l a r P l u g C o n n e c t o r s

P R O P E R U S E G U I D E L I N E S

C u m u l a t i v e T r a u m a D i s o r d e r s c a n r e s u l t f r o m t h e p r o l o n g e d u s e o f m a n u a l l y p o w e r e d h a n d t o o l s . H a n d t o o l s a r e i n t e n d e d f o r o c c a s i o n a l u s e a n d l o w v o l u m e

a p p l i c a t i o n s . A w i d e s e l e c t i o n o f p o w e r e d a p p l i c a t i o n e q u i p m e n t f o r e x t e n d e d - u s e , p r o d u c t i o n o p e r a t i o n s i s a v a i l a b l e .

S t a t i o n a r y J a w

F r o n t o f T o o l

D i e A s s e m b l y

M o v i n g J a w

R a t c h e t

A d j u s t m e n t

W h e e l

M o v i n g H a n d l e

S t a t i o n a r y

H a n d l e

P R O - C R I M P E R I I I

H a n d T o o l F r a m e

P i v o t

P i n

B a c k o f

T o o l

T h e P R O - C R I M P E R I I I H a n d

T o o l i s a C o m m e r c i a l " g r a d e t o o l

a n d i s d e s i g n e d p r i m a r i l y f o r f i e l d

i n s t a l l a t i o n , r e p a i r , m a i n t e n a n c e

w o r k , o r p r o t o t y p i n g i n i n d u s t r i a l ,

s p e c i f i c a t i o n , b u t m a y n o t c o m p l y w i t h

o t h e r f e a t u r e p a r a m e t e r s o f t h e

s p e c i f i c a t i o n . T y c o E l e c t g r o n i c s o f f e r s a

v a r i e t y o f t o o l s t o s a t i s f y y o u r

p e r f o r m a n c e r e q u i r e m e n t s . F o r

a d d i t i o n a l i n f o r m a t i o n , c o n t a c t t h e

T o o l i n g A s s i s t a n c e C e n t e r a t

1 - 8 0 0 - 7 2 2 - 1 1 1 1 .

c o m m e r c i a l , o r i n s t i t u t i o n a l

a p p l i c a t i o n s . P r o d u c t c r i m p e d

w i t h t h i s t o o l w i l l m e e t t h e

c r i m p h e i g h t r e q u i r e m e n t f o r

h a n d t o o l s i n t h e a p p r o p r i a t e

1 1 4 a p p l i c a t i o n

P R O - C R I M P E R I I T O O L I N G C O N N E C T O R C O N D U C T O R C A B L E

H a n d T o o l

a n d D i e A s s y

D i e

A s s y

H a n d T o o l

F r a m e

E M T

M o d u l a r

P l u g

A W G

I n s u l a t i o n

D i a m e t e r

( m m )

S t r i p

L e n g t h

( m m )

O u t e r

D i a m e t e r

( m m )

7 9 0 1 6 3 - 1 7 9 0 1 6 3 - 2

3 5 4 9 4 0 2

3 3 6 3 3 0 - 1

3 3 6 3 3 0 - 2

2 6 2 4 0 8 0 1 0 0 3 5 / 5

5 . 0 - 6 . 0

7 9 0 1 6 3 - 3 7 9 0 1 6 3 - 4

3 5 4 9 4 0 - 2

3 3 6 4 3 9 - 1

2 6 - 2 4 0 . 8 0 - 1 . 0 0 3 5 + / - 5

7 9 0 1 6 3 - 5 7 9 0 1 6 3 - 6 3 3 6 4 6 2 - 1 6 . 0 - 7 . 0

Figure 11 . I N T R O D U C T I O N

PROCRIMPER III Hand Tool Assembly consists ofthe Hand Tool Frame 3549402, and the appropriatedie assembly, as listed in the table in Figure 1. Thedie assembly consists of an insulation and connectorshield stuffer, a housing support, housing guides, dieretaining pins, and mounting hardware.

D i m e n s i o n s i n t h i s i n s t r u c t i o n s h e e t a r e i n

m i l l i m e t e r s . F i g u r e s a n d i l l u s t r a t i o n s a r e f o r

i d e n t i f i c a t i o n , o n l y , a n d a r e n o t d r a w n t o s c a l e .

2 . D E S C R I P T I O N ( F i g u r e 1 a n d F i g u r e 2 )

This tool features a tool frame, a stationary jaw andhandle, a moving jaw, a moving handle, and anadjustable ratchet that ensures full and completecrimping of product. The tool frame holds a dieassembly with insulation and connector shield andcontact stuffer.

N O T E


2/4


3/4

4 0 8 - 8 7 3 8

P R O - C R I M P E R I I I H a n d T o o l s a n d D i e A s s e m b l i e s f o r t h e E M T M o d u l a r P l u g

3 o f 4 R e v O

Figure 3

M o d u l a r P l u g

C o n n e c t o r

H o u s i n g

S u p p o r t

C a b l e S h i e l d

W i r e S t u f f e r

H o l d i n g S c r e w

C o n t a c t S t u f f e r

6 . 0 2 + / - 0 . 1 3

0 . 8 0 M a x

H o u s i n g

C o n t a c t

W i r e

H o l d e r

I n s u l a t i o n

S h i e l d

S t u f f e r

5 . C R I M P H E I G H T I N S P E C T I O N

Figure 3 shows a cutaway of a typical terminatedplug and the required location of the conductors. Avisual inspection through the plastic housing of theplug should reveal whether the conductors are withinthe acceptable range.

Inspect the connector for proper crimp height usingan indicator with needlepoint probes. Refer toFigure 3 for the appropriate crimp height

measurement. If necessary, adjust the crimp heightas described in Paragraph 6.1, Crimp HeightAdjustment.

6 . A D J U S T M E N T S

6 . 1 . C r i m p H e i g h t A d j u s t m e n t ( F i g u r e 4 )

1. Remove the lockscrew from the ratchetadjustment wheel.

2. With a screwdriver, adjust the ratchet wheelfrom the opposite side of the tool.

3. While facing the ratchet adjustment wheel,adjust the crimp.

a. If a tighter crimp is required, rotate theadjustment wheel counterclockwise to ahighernumbered setting.

b. If a looser crimp is required, rotate theadjustment wheel clockwise to alowernumbered setting.

4. Replace the lockscrew.

5. Make a sample crimp and measure the crimpheight. If the dimension is acceptable, secure thelockscrew. If the dimension is unacceptable,continue to adjust the ratchet, and again measurea sample crimp.

If correct crimp height cannot be obtained, the tooland/or dies must be replaced. Refer to Section 8,PARTS REPLACEMENT.

6 . 2 . W i r e S t u f f e r A d j u s t m e n t

If the wire stuffer is not assembled onto the insulationstuffer (or there are doubts about a correctadjustment of these two parts), proceed as describedbelow.

Figure 4

S c r e w d r i v e r

L o c k - S c r e w

( T y p )

R a t c h e t

A d j u s t m e n t

W h e e l


4/4

4 0 8 - 8 7 3 8

P R O - C R I M P E R I I I H a n d T o o l s a n d D i e A s s e m b l i e s f o r t h e E M T M o d u l a r P l u g

R e v O 4 o f 4

1. Assemble the wire stuffer onto the insulationstuffer with the 440 UNC X .621 In. socket headcap screw included with the die set.

D o N O T t i g h t e n t h e s c r e w . L o o s e n i t i f i t i s

a l r e a d y t i g h t .

2. Open the tool jaws and insert a plug assembly

(without the cable) into the jaw cavity.3. Squeeze the tool handles and keep themclosed.

4. Insert a key into the wire stuffer holding screwand tighten it.

5. Open the tool and remove the crimped plug. Atthis point the wire stuffer is held in its properposition.

7 . M A I N T E N A N C E A N D I N S P E C T I O N

7 . 1 . D a i l y M a i n t e n a n c e

Tyco Electronics recommends that operators of thetool be made aware of, and are responsible for, thefollowing steps of daily maintenance.

1. Remove dust, moisture, and any othercontaminants from the tool with a clean, soft brush,or a clean, soft, lintfree cloth. Do NOT use hard orabrasive objects that could damage the tool.

2. Make certain that the retaining pins are in placeand that they are secured with retaining rings.

3. All pins, pivot points, and bearing surfacesshould be protected with a thin coat of any goodgrade SAE 20 motor oil.

D o n o

t o i l e x c e s s i v e l y .

4. When the tool is not in use, keep the handlesclosed to prevent objects from becoming lodged inthe crimping jaws.

5. Store the tool in a clean, dry area.

7 . 2 . P e r i o d i c I n s p e c t i o n

Regular inspection of the tool should be performed byquality control personnel. A record of the scheduledinspections should remain with the tool or be suppliedto supervisory personnel responsible for the tool.

Inspection frequency should be based on:

S amount of use;S working conditions;S operator training and skill; andS established company standards.

7 . 3 . V i s u a l I n s p e c t i o n

The crimping dies should be inspected on a regularbasis to ensure they have not become worn ordamaged. Inspect the crimp sections for flattened,chipped, worn, or broken areas. If damage orabnormal wear is evident, the tool must be replaced.Refer to Section 8, PARTS REPLACEMENT.

1. Remove all lubrication and accumulated film byimmersing the tool (handles partially closed) in asuitable commercial degreaser that will NOT affectpaint or plastic material.

2. Make certain that the retaining pins are in placeand that they are secured with retaining rings.

3. Close the tool handles until the ratchet releases,and then allow the handles to open freely. If theydo not open quickly and fully, the spring isdefective and must be replaced.

4. Inspect the tool frame for wear or damage,paying particular attention to the tool jaws and thepivot points. If damage is evident, replace it. Ifdamage is not evident, lubricate the pivot point andreturn the tool to service.

5. Check the dies occasionally to make sure thedies are not broken or chipped. If damage isevident, replace them.

8 . C U S T O M E R R E P L A C E A B L E P A R T S

Customerreplaceable parts are shown in Figure 1.Available separately, PROCRIMPER III Repair Kit6792211 includes a replacement nut and a variety ofpins, rings, screws, and springs. If the dies aredamaged or worn excessively, they must be replaced.Order the repair kit and replaceable parts throughyour Tyco Electronics Representative, or call18005265142, or send a facsimile of yourpurchase order to 17179867605, or write to:

CUSTOMER SERVICE (3835)TYCO ELECTRONICS CORPORATIONP.O. BOX 3608HARRISBURG, PA 171053608

9 . R E V I S I O N S U M M A R Y

New release per EC 0990092904

N O T E

N O T E

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