Instruction Sheet PRO-CRIMPER*IIIHandCrimping ToolAssembly58448-2 408--9357 WithDieAssembly58448-3 10 Mar 11 RevE PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awide selection ofpowered application equipmentforextended--use,production operationsisavailable. Locator Stationary Jaw Assembly Front of Tool Pivot Pin (Locator Side) PRO--CRIMPER III Hand Crimping Tool Frame 354940-- 1 (408--9930) Die Assembly Moving Jaw Back of Tool (Wire Side) Ratchet Adjustment Wheel The PRO--CRIMPER IIIHand Crimping Tool isa “Commercial”grade tool Stationary Handle and isdesigned primarilyforfield installation,repair,maintenance work,or prototyping in industrial,commercial,orinstitutional applications.Product crimped with thistool will meetthe crimp heightrequirementforhand toolsin Movable Handle the appropriate 114 seriesspecification,butmaynotcomplywith otherfeature parametersofthe specification.TEoffersa varietyoftoolsto satisfyyour performance requirements.Foradditional information,contactthe Tooling Assistance Centerat1--800--722--1111. Wire T TE ED Diiee L Loc ocaattor or ProductFamily} SizeRange InsulationDiameter(Max) StripLength Assembly Assembly{ (AWG) (mm[in.]) (mm[in.]) AMPLIMITE* 28--24 1.02 [.040] H HD DP P----2 20 0 C Co onnector nnector 5 58448 8448--3 3 1 1214310 214310--1 1 2 2.54 54 [.100 [ 100]] Crimp Snap--In Contacts 24--20 1.52 [.060] with Insulation Support { Supplied with die assembly. Also available separately. } Contact the Tooling Assistance Center or Product Information at the numberslisted below for specificcontact part numbers. Figure 1 1. INTRODUCTION 2. DESCRIPTION PRO--CRIMPER III Hand Crimping Tool Assembly The tool features a tool frame with a stationary jaw 58448--2 consists of Die Assembly 58448--3 and and handle, moving jaw, moving handle, and PRO--CRIMPER III Hand Crimping Tool Frame adjustable ratchet that ensures full contact crimping. 354940--1. The die assembly consists of crimping The tool frame holds a die assembly with two dies and a locator assembly. crimping chambers. See Figure 1. Read these instructions thoroughly before crimping The die assembly features a wire anvil, insulation any contacts. anvil, wire crimper, and insulation crimper. Dimensions in this instruction sheet are in metric Die retaining pins and die retaining screws are used NOTE units [with U.S. customary units in brackets]. to position and secure the dies in the tool frame. Figures are not drawn to scale. i Attached to the outside of the frame is a locator assembly, which contains a locator and contact Reasons for reissue of this instruction sheet are retainer. A nut is used on the upper die retaining provided in Section 10, REVISION SUMMARY. screw to hold the locator assembly in place. E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change. 1 of 5 All Rights Reserved PRODUCT INFORMATION 1--800--522--6752 For latest revision and Regional Customer Service, TE logo is a trademark. visit our website at www.te.com LOCB *Trademark. Other product names, logos, or company names might be trademarks of their respective owners. 408-9357 Locator Nut Assembly Tool Frame Locator Chamfered Long Die Retaining Pins Edge Insulation (Supplied with Locator Assembly) Crimper Short Die Wire Crimper Retaining Pins Offset Wire Anvil Insulation Chamfered Short Die Retaining Long Die Retaining Anvil Edge Screw Screw Figure 2 the anvils and crimpers in place, then tighten both 3. INSTALLATIONANDREMOVALOFDIEASSEMBLY die retaining screws. ANDLOCATORASSEMBLY (Figure 2) 9. Remove the pin from the center hole in the 1. Open the tool handles, and remove the two die locator assembly. Place the locator assembly over retaining screws from the tool jaws. the end of the long die retaining screw and long die 2. Place the wire anvil and insulation anvil so that retaining pins. Position the locator assembly the chamfered sides and marked surfaces face against the side of the tool jaw. outward, when mounted in the moving jaw of the 10. Place the nut onto the end of the long screw tool frame. and tighten the nut enough to hold the locator 3. Insert the two short die retaining pins through assembly in place, while still allowing the locator to slide up and down. the tool frame and into the anvils. 11. To disassemble, close the tool handles until the 4. Insert the short die retaining screw through the ratchet releases, remove the nut, the locator jaw and through both anvil dies, and tighten the assembly, the two die retaining screws, and the screw just enough to hold the dies in place. Do not four die retaining pins, and slide the anvils and tighten the screw completely at this time. crimpers out of the tool jaws. 5. Place the wire crimper and insulation crimper so that their chamfered sides and their marked 4. CRIMPINGPROCEDURE surfaces face outward, when mounted in the This tool is provided with a crimp adjustment stationary jaw of the tool frame. NOTE feature. Initially, the crimp height should be 6. Insert the two long die retaining pins (supplied verified as specified in Section 5, CRIMP i with the locator assembly) through the tool frame HEIGHT INSPECTION, and Section 6, and into the crimpers. RATCHET (Crimp Height) ADJUSTMENT, before using the tool to crimp desired contacts. 7. Insert the long die retaining screw through the jaw and through both crimper dies, and tighten the Refer to Figure 1, and select wire of the specified size screw just enough to hold the dies in place. Do not and insulation diameter. Strip the wire to the length tighten the screw completely at this time. indicated, taking care not to nick or cut wire strands. Select an applicable contact and identify the 8. Carefully close the tool handles, making sure appropriate crimping chamber according to the wire that the anvils and crimpers align properly. size markings on the tool. Continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold Refer to Figure 3, and proceed as follows: 2 of 5 RevE 408-9357 1. Hold the tool so that the front (locator side) is The crimped contact may stick in the crimping NOTE facing you. Squeeze tool handles together and area, but can be removed by pushing downward allow them to open fully. on the top of the locator (see Figure 3). i 2. Insert the contact—mating end first—into the hole in the locator which corresponds with the 7. Check the contact crimp height as described in appropriate crimping chamber. Make sure that the Section 5, CRIMP HEIGHT INSPECTION. If open “U” of the wire barrel and insulation barrel necessary, adjust the crimp height as described in face the stationary jaw. Section 6, CRIMP HEIGHT ADJUSTMENT. Do NOT attempt to close the tool handles when CAUTION locator contact retainer is between the dies. Damage to the tool jaws or locator may result. ! 5. CRIMPHEIGHTINSPECTION Crimp height inspection is performed through the use 3. Slide the locator contact retainer out from of a micrometer with a modified anvil, commonly between the dies (spring tension will pull the referred to as a crimp--height comparator. TE does locator down). Make sure that the wire stop enters not manufacture or market crimp--height comparators. the contact wire stop slot between the wire barrel Detailed information on obtaining and using and contact shoulder. Release contact retainer. crimp--height comparators can be found in instruction sheet 408--7424. Make sure that both sides of the contact CAUTION insulation barrel are started evenly into the crimping chamber. Do NOT attempt to crimp an Proceed as follows: ! improperly positioned contact. 1. Refer to Figure 4 and select the maximum size 4. Hold the contact in position, and squeeze the wire for the crimping chamber. tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT 2. Refer to Section 3, CRIMPING PROCEDURE, deform insulation barrel or wire barrel. and crimp the contact accordingly. 5. Insert stripped wire into contact insulation and 3. Using a crimp height comparator, measure the wire barrels until it is butted against the wire stop, wire barrel crimp height as shown in Figure 4. If the as shown in Figure 3. crimp height conforms to that shown, the tool is 6. Holding the wire in place, squeeze tool handles considered dimensionally correct. If not, the tool together until ratchet releases. Allow tool handles must be adjusted. Refer to Section 6, CRIMP to open and remove crimped contact. HEIGHT ADJUSTMENT. Locator Back of Tool (Wire Side) Contact Tool Stationary Retainer Jaw Wire Wire Strip Length Tool Wire Size Markings Locator in Wire Inserted to Contact Wire Locator Wire Stop Stop Slot Figure 3 RevE 3 of 5 408-9357 Position Point 7. MAINTENANCE on Center of Wire Barrel Ensure that the tool and dies are clean by wiping Opposite them with a clean, soft cloth. Remove any debris with Spindle Seam 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. Crimp Modified Height Anvil 8. VISUALINSPECTION WireSize(AWG) CrimpHeightDimension (Max) +0.05mm[+.002in.] The crimping dies should be inspected on a regular 24 0.724 [.0285] basis to ensure that they have not become worn or 20 0.749 [.0295] damaged. Inspect the crimping chambers for flattened, chipped, worn, or broken areas. If damage Figure 4 or abnormal wear is evident, the tool must be replaced. See Section 9, REPLACEMENT. 6. RATCHET(CrimpHeight)ADJUSTMENT (Figure 5) 1. Remove the lockscrew from the ratchet 9. REPLACEMENT adjustment wheel. 2. With a screwdriver, adjust the ratchet wheel Customer--replaceable parts are shown in Figure 1. from the locator side of the tool. 3. Observe the ratchet adjustment wheel. If a Available separately, PRO--CRIMPER III Hand tighter crimp is required, rotate the adjustment Crimping Tool Repair Kit 679221--1 includes a wheel counterclockwise to a higher--numbered replacement nut and a variety of pins, rings, screws, setting. If a looser crimp is required, rotate the and springs. adjustment wheel clockwise to a lower--numbered setting. If the dies are damaged or worn excessively, they must be replaced. 4. Re--assemble the lockscrew. 5. Make a sample crimp and measure the crimp Order repair kit and replaceable parts through your height. TE representative, or call 1--800--526--5142, or send a 6. If the dimension is unacceptable, continue to facsimile of your purchase order to 717--986--7605, or adjust the ratchet, and again measure a sample write to: crimp. CUSTOMER SERVICE (38--35) TYCO ELECTRONICS PO BOX 3608 HARRISBURG PA 17105--3608 Screwdriver 10. REVISIONSUMMARY Revisions to this instruction sheet include: S Updated document to corporate requirements. Ratchet Adjustment Wheel Lockscrew (Typ) Figure5 4 of 5 RevE 408-9357 DieAssembly58448-3CanBeUsedIntheFollowingTools: PRO-CRIMPER III Hand Tool 354940-1 SDE PEW-12Hand Tool 9-1478240-0 (Instruction Sheet408-9930) (Instruction Sheet408-8851) SDE Bench Terminator1490076-2 626Adapter679304-1 (CustomerManual 409-10052) (Instruction Sheet408-4070) BatteryTool (Pin Die)1213890-1, -2 BatteryTool (Shouldered Die)1725837-1, -2 (CustomerManual 409-10065) (CustomerManual 409-10053) RevE 5 of 5