Instruction Sheet PRO-CRIMPER* III Hand  Crimping Tool Assembly 58514-1 408-9973 with Die Assembly 58514-2 12 OCT 11 Rev C 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. Locator Assembly Stationary Jaw Pivot Pin (Supplied with Die Assembly) Back of Tool (Wire Side) PRO-CRIMPER III  Hand Crimping Tool  Die Frame 354940-1  Assembly (408-9930) Moving Jaw Stationary Handle Ratchet Adjustment Wheel Moving Handle WIRE TE DIE TE LOCATOR CONTACT SIZE STRIP LENGTH ASSEMBLY ASSEMBLY† FAMILY‡ INSUL DIA (AWG) (mm [In.]) 26-22 1.27 to 2.92 Miniature [.050 to .115] 20-18 3.96 +/- .380 58514-2 58515-1 Rectangular [.156 +/- .015] Contacts .64 to .127 26-24 [.025 to .050] † Supplied with the die assembly. Also available separately. ‡ Call the TOOLING ASSISTANE CENTER or PRODUCT INFORMATION (see below) for product part numbers. Figure 1 1. INTRODUCTION 2. DESCRIPTION (Figure 1 and Figure 2) PRO-CRIMPER III Hand Crimping Tool Assembly The tool features a tool frame with a stationary jaw 58514-1 consists of Die Assembly 58514-2 and  and handle, a moving jaw, a moving handle, and an PRO-CRIMPER III Hand Crimping Tool Frame adjustable ratchet that ensures full contact crimping. 354940-1. The die assembly consists of crimping dies The tool frame holds a die assembly with three and a locator assembly. crimping sections. Read these instructions thoroughly before crimping The die assembly features a wire anvil, an insulation any contacts. anvil, a wire crimper, and an insulation crimper. Dimensions on this sheet are in millimeters [with Attached to the outside of the frame is a locator NOTE inch equivalents provided in brackets]. Figures and assembly, which contains a locator, a spring retainer, illustrations are for identification only and are not and a contact support. i drawn to scale. Die retaining pins and die retaining screws are used to Reasons for reissue are provided in Section 11, position and secure the dies in the tool frame. A nut is REVISION SUMMARY. used on the upper die retaining screw to hold the locator assembly in place. © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-9973 Tool Frame Locator Nut Assembly Chamfer Die Retaining Insulation Pins Crimper Wire Crimper Offset Wire Anvil Die Retaining Insulation Die Retaining Chamfer Screws Anvil Screws Figure 2 anvils and crimpers in place, then tighten both die 3. INSTALLATION AND REMOVAL OF DIE SET AND retaining screws. LOCATOR ASSEMBLY (Figure 2) 1. Open the tool handles and remove the two die 10. Place the locator assembly over the end of the retaining screws from the tool jaws. long screw, and position the locator assembly against the side of the tool jaw. 2. Place the wire anvil and insulation anvil so that their chamfered sides and their marked surfaces 11. Place the nut onto the end of the long screw and face outward, when mounted in the moving jaw of tighten the nut enough to hold the locator assembly the tool frame. in place, while still allowing the locator to slide up and down. 3. Insert the two die retaining pins. 12. 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 four screw just enough to hold the dies in place. Do not die retaining pins, and slide the anvils and crimpers tighten the screw completely at this time. out of the tool jaws. 5. Place the wire crimper and insulation crimper so that their chamfered sides and their marked 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) surfaces face outward, when mounted in the The contact support is preset prior to shipment, but NOTE stationary jaw of the tool frame. minor adjustment may be necessary. 6. Insert the two die retaining pins. i 7. Insert the long die retaining screw through the 1. Make a sample crimp and determine if the jaw and through both crimper dies, and tighten the contact is straight, bending upward, or bending screw just enough to hold the dies in place. Do not downward. tighten the screw completely at this time. 2. .If adjustment is required, loosen the screw that 8. Carefully close the tool handles, making sure that holds the contact support onto the locator assembly. the anvils and crimpers align properly. The ratchet has detents that create audible clicks NOTE 9. Continue closing the tool handles until the ratchet as the tool handles are closed. in the tool frame has engaged sufficiently to hold the i Rev C 2 of 6 408-9973 3. Place a contact with wire into the proper nest and the length indicated in Figure 1, taking care not to nick close the tool handles until the ratchet reaches the or cut wire strands. Select an applicable contact and sixth click, or until the contact support touches the identify the appropriate crimp section according to the contact. wire size markings on the tool. Refer to Figure 3 and proceed as follows: 4. Slightly loosen the nut that holds the locator assembly onto the tool frame. 1. Hold the tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them 5. Move the contact support as required to eliminate to open fully. the bending of the contact. 2. Holding the contact by the mating end, insert the 6. Tighten the nut and close the handles until the contact - insulation barrel first - through the front of ratchet releases. the tool and into the appropriate crimp section. 7. Remove and inspect the contact. 3. Position the contact so that the mating end of the contact is on the locator side of the tool, and so that 8. Make another sample crimp. If the contact is the open "U" of the wire and insulation barrels must straight, tighten the contact support screw. If the face the top of the tool. Place the contact up into the contact is still being bent during crimping, repeat the nest so that the movable locator drops into the slot adjustment procedure. in the contact. Refer to Figure 3. Butt the front end of the wire barrel against the movable locator. 5. CRIMPING PROCEDURE This tool is provided with a crimp adjustment Make sure that both sides of the insulation barrel NOTE CAUTION feature. Initially, the crimp height should be verified are started evenly into the crimping section. Do not as specified in Figure 4. Refer to Section 6, Crimp attempt to crimp an improperly positioned contact. i ! Height Inspection, and Section 7, RATCHET (Crimp Height) Adjustment, to verify crimp height before using the tool to crimp desired contacts and 4. Hold the contact in position and squeeze the tool wire sizes. handles together until ratchet engages sufficiently to hold the contact in position. Do NOT deform Refer to the table in Figure 1 and select wire of the insulation barrel or wire barrel. specified size and insulation diameter. Strip the wire to Locator Contact Support Contact (Typ) Adjustment Back of Tool Screw for (Wire Side) Contact  Support Strip Length Locator in Wire Wire Stop Slot Inserted to Stop Wire Figure 3 Rev C 3 of 6 408-9973 5. Insert stripped wire into contact insulation and the tool must be adjusted. Refer to Section 7, wire barrels until it is butted against the wire stop, as RATCHET (Crimp Height) ADJUSTMENT. shown in Figure 3. 7. RATCHET (Crimp Height) ADJUSTMENT 6. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to 1. Remove the lockscrew from the ratchet open and remove crimped contact. adjustment wheel. The crimped contact may stick in the crimping area, 2. With a screwdriver, adjust the ratchet wheel from NOTE but the contact can be easily removed by pushing the locator side of the tool (see Figure 5). downward on the top of the locator (see Figure 3). i Screwdriver 7. Check the contact's crimp height as described in Section 6, Crimp Height Inspection. If necessary, adjust the crimp height as described in Section 7, RATCHET (Crimp Height) ADJUSTMENT. 6. CRIMP HEIGHT INSPECTION RATCHET (Crimp Height) inspection is performed through the use of a micrometer with a modified anvil, commonly referred to as a crimp-height comparator. Ratchet TE does not manufacture or market crimp-height Adjustment comparators. Detailed information on obtaining and Wheel using crimp-height comparators can be found in instruction sheet 408-7424. Proceed as follows: Lockscrew 1. Refer to Figure 4 and select a wire (maximum (Typ) size) for each crimp section listed. Figure 5 3. Observe the ratchet adjustment wheel. If a tighter Position Point crimp is required, rotate the adjustment wheel on Center of COUNTERCLOCKWISE to a higher-numbered Wire Barrel setting. If a looser crimp is required, rotate the Opposite adjustment wheel CLOCKWISE to a lower- Seam numbered setting. 4. Replace the lockscrew. Modified “A” 5. Make a sample crimp and measure the crimp Anvil height. If the dimension is acceptable, replace and secure the lockscrew. If the dimension is CRIMP SECTION CRIMP HEIGHT unacceptable, continue to adjust the ratchet, and WIRE SIZE (Wire Size DIMENSION “A” AND again measure a sample crimp. AWG (Max) Marking) TOLERANCE (±) 22 26-22 8. MAINTENANCE .71 ±.05 [.028 ± .002] 24 26-24 Ensure that the tool and dies are clean by wiping them with a clean, soft cloth. Remove any debris with a .97 ±.05 18 20-18 clean, soft brush. Do not use objects that could [.038 ± .002] damage the tool. When not in use, keep handles Figure 4 closed to prevent objects from becoming lodged in the crimping dies, and store in a clean, dry area. 2. Refer to Section 5, CRIMPING PROCEDURE, and crimp the contact(s) accordingly. 3. Using a crimp height comparator, measure the wire barrel crimp height as shown in Figure 4. If the crimp height conforms to that shown in the table, the tool is considered dimensionally correct. If not, Rev C 4 of 6 408-9973 9. VISUAL INSPECTION Order the repair kit and replaceable parts through your TE representative, or call 1-800-526-5142, or send a The crimping dies should be inspected on a regular facsimile of your purchase order to 1-717-986-7605, or basis to ensure that they have not become worn or write to: damaged. Inspect the crimp sections for flattened, chipped, worn, or broken areas. If damage or CUSTOMER SERVICE (038-035) abnormal wear is evident, the tool must be replaced. TYCO ELECTRONICS CORPORATION See Section 10, REPLACEMENT. PO BOX 3608 HARRISBURG PA 17105-3608 10. REPLACEMENT 11. REVISION SUMMARY Customer-replaceable parts are shown in Figure 1. Revisions to this instruction sheet include: Available separately, PRO-CRIMPER III Hand Crimping Tool Repair Kit 679221-1 includes a • Changed company name and logo replacement nut and a variety of pins, rings, screws, and springs. If the dies are damaged or worn excessively, they must be replaced. Rev C 5 of 6 408-9973 Rev C 6 of 6