Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly And 408-4064 Die Set 58517-[ ] 10 MAY 12 Rev F 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 Stationary Jaw (Supplied with Back of Tool Die Assembly) (Wire Side) Pivot Pin Front of Tool (Locator Side) PRO-CRIMPER III Hand Crimping Tool Frame 354940-1 Moving Jaw (Instruction Die Assembly Sheet 408-9930) Ratchet Adjustment Wheel The PRO-CRIMPER III Hand Crimping Tool is a “Commercial” grade tool and is designed primarily for field installation, repair, maintenance work, or prototyping in industrial, commercial, or institutional applications. Product Handle crimped with this tool will meet the crimp height requirement for hand tools in the appropriate Application Specification (114-series), but may not comply with other feature parameters of the specification. TE Connectivity offers a Moving variety of tools to satisfy your performance requirements. For additional Jaw information, contact the Tooling Assistance Center at 1-800-722-1111. WIRE LOCATOR PRO-CRIMPER DIE ASSEMBLY CONTACT PART SIZE INSUL DIA STRIP LENGTH III HAND TOOL PART NUMBER FAMILY NUMBER‡ (AWG) (mm [in.]) (mm [in.]) 58517-1 58517-2 189590-1 CST 100 0.89-1.65 2.54-2.92 58517-3 58517-4 1424907-1 CST 100 II 26-22 [.035-.065] [.100-.125] None 58517-5 • 1901843-1 CST 100 II • Bench Machine/Battery and ‡ Supplied with the die assembly. Also available ‡‡ Contact the PRODUCT INFORMATION CENTER for specific contact part SDE-SA Hand Tool Only separately. numbers. Figure 1 1. INTRODUCTION Reasons for reissue are provided in Section 11, REVISION SUMMARY. PRO-CRIMPER III Hand Crimping Tool Assembly 58517-1 consists of Die Assembly 58517-2 and 2. DESCRIPTION (See Figure 1 and Figure 2.) PRO-CRIMPER III Hand Tool Frame 354940-1. See Figure 1. The tool features a tool frame with a stationary jaw and handle, a moving jaw, a moving handle, and an The die assembly consists of crimping dies and a adjustable ratchet that ensures full contact crimping. locator assembly. The tool frame holds a die assembly with one crimping Read these instructions thoroughly before crimping section. any contacts. The die assembly features a wire anvil, an insulation Dimensions on this sheet are in millimeters [with NOTE anvil, a wire crimper, and an insulation crimper. inch equivalents provided in brackets]. Figures and illustrations are for identification only and are not Attached to the outside of the frame is a locator, which i drawn to scale. holds and helps to position the contact. ©2012 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, *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. ORIGINAL INSTRUCTIONS 408-4064 Tool Frame Adjustment Screw (or Bench Nut (See Figure 3) Nut Machine, or Ratched Hand Tool) Washer Die Retaining Pins Locator Insulation Chamfer Crimper Wire Crimper Insulation Anvil Offset Die Retaining Screws Wire Anvil Chamfer Figure 2 Die retaining pins and die retaining screws are used to 8. Carefully close the tool handles, making sure position and secure the dies in the tool frame. A that the anvils and crimpers align properly. washer and nut is used on the lower die retaining Continue closing the tool handles until the ratchet screw to hold the locator in place. in the tool frame has engaged sufficiently to hold the anvils and crimpers in place, then tighten both die retaining screws. 3. INSTALLATION AND REMOVAL OF DIE SET AND LOCATOR ASSEMBLY (Figure 2) 9. Place the locator over the end of the long 1. Open the tool handles and remove the two die screw, and position the locator against the side of retaining screws from the tool jaws. the tool jaw. 2. Place the wire anvil and insulation anvil in the 10. Place the washer and nut onto the end of the moving jaw so that their chamfered sides and long screw. Align the locator slot with the their marked surfaces face outward, when crimping section and carefully tighten the nut. mounted in the moving jaw of the tool frame. 11. To disassemble, close the tool handles until 3. Insert the two die retaining pins. the ratchet releases, remove the nut, the washer, the locator, the two die retaining screws, and the 4. Insert the long die retaining screw through the four die retaining pins, and slide the anvils and jaw and through both anvil dies, and tighten the crimpers out of the tool jaws. screw just enough to hold the dies in place. Do not tighten the screw completely at this time. 4. CRIMPING PROCEDURE 5. Place the wire crimper and insulation crimper This tool is provided with a crimp adjustment NOTE in the stationary jaw so that their chamfered sides feature. Initially, the crimp height should be verified and their marked surfaces face outward, when as specified in Figure 4. Refer to Section 6, Crimp i mounted in the stationary jaw of the tool frame. Height Inspection, and Section 7, Crimp Height Adjustment, to verify crimp height before using the 6. Insert the two die retaining pins. tool to crimp desired contacts and wire sizes. 7. Insert the short die retaining screw through the jaw and through both crimper dies, and tighten the screw just enough to hold the dies in place. Do not tighten the screw completely at this time. Rev F 2 of 5 408-4064 Refer to the table in Figure 1 and select wire of the 4. Insert stripped wire into contact insulation and specified size and insulation diameter. Strip the wire to wire barrels until it is butted against the wire stop the length indicated in Figure 1, taking care not to nick on the contact, as shown in Figure 3. or cut wire strands. Select an applicable contact and 5. Holding the wire in place, squeeze tool handles identify the appropriate die assembly according to the together until ratchet releases. Allow tool handles wire size markings on the die. Refer to Figure 3 and to open and remove crimped contact. proceed as follows: 6. Check the contact's crimp height as described 1. Hold the tool so that the back (wire side) is in Section 6, Crimp Height Inspection. If facing you. Squeeze tool handles together and necessary, adjust the crimp height as described allow them to open fully. in Section 7, CRIMP HEIGHT ADJUSTMENT. 2. Holding the contact by the insulation barrel, insert the contact—mating end first—into the 5. CONTACT SUPPORT ADJUSTMENT (Figure 3) locator slot. Position the contact so that the open 1. .Make a sample crimp according to Section 4, “U” of the wire and insulation barrels face the top CRIMPING PROCEDURE. If the crimp is out of of the tool. Make sure the contact butts against alignment, adjustment is required. the adjustment screw. Check that the contact is centered with the die assembly wire and 2. To move the contact from side-to-side, loosen insulation anvils. If adjustment is required, refer to the nut that holds the locator to the frame and Section 5, CONTACT SUPPORT ADJUSTMENT. slide the locator until the contact is properly positioned. Hold the locator in place and tighten Make sure that both sides of the insulation barrel NOTE the nut. are started evenly into the crimping section. Do not attempt to crimp an improperly positioned contact. 3. To move the contact in or out, loosen the nut i on the adjustment screw and turn the screw until the contact is properly positioned. Hold the screw 3. Hold the contact in position and squeeze the in place and tighten the nut. tool handles together until ratchet engages sufficiently to hold the contact in position. Do 4. If the crimp is still out of alignment, repeat the NOT deform insulation barrel or wire barrel. adjustment procedure.CRIMP HEIGHT INSPECTION. The ratchet has detents that create audible clicks NOTE as the tool handles are closed. i Adjustment Back of Tool “A” Screw (Wire Side) Strip Length Locator Wire Inserted Wire Inserted to in Contact Contact Wire Stop TOOL DIMENSION A 58517-1, 58517-2, 2.641 [.104] Locator Slot Wire 58517-3, 58517-4 4.191 [.165] 58517-5 Figure 3 Rev F 3 of 5 408-4064 . Screwdriver Ratchet Adjustment CRIMP SECTION CRIMP HEIGHT WIRE SIZE Pawl (WIRE SIZE DIM (A) AND AWG (Max) MARKING) TOLERANCE (±) 0.79±0.05 22 26-22 [.031±.002] Lockscrew Figure 4 6. CRIMP HEIGHT INSPECTION Figure 5 Crimp height inspection is performed through the 8. MAINTENANCE use of a micrometer with a modified anvil, commonly referred to as a crimp height comparator. Ensure that the tool and dies are clean by wiping them Tyco Electronics does not market crimp height with a clean, soft cloth. Remove any debris with a comparators. Refer to Instruction Sheet 408-7224 clean, soft brush. Do not use objects that could for detailed information on obtaining and using a damage the tool. When not in use, keep handles crimp height comparator. closed to prevent objects from becoming lodged in the crimping dies, and store in a clean, dry area. Proceed as follows: 9. VISUAL INSPECTION 1. Refer to Figure 4 and select a wire (maximum size) for the crimp section. The crimping dies should be inspected on a regular basis to ensure that they have not become worn or 2. Refer to Section 4, CRIMPING PROCEDURE, damaged. Inspect the crimp section for flattened, and crimp the contact(s) accordingly. chipped, worn, or broken areas. If damage or abnormal wear is evident, the tool must be replaced. 3. Using a crimp height comparator, measure the See Section 10, REPLACEMENT. wire barrel crimp height as shown in Figure 4. If the crimp height conforms to that shown in the 10. REPLACEMENT table, the tool is considered dimensionally correct. If not, the tool must be adjusted. Refer to Customer-replaceable parts are shown in Figure 1. Section 7, CRIMP HEIGHT ADJUSTME Available separately, PRO-CRIMPER III Hand Tool Repair Kit 679221-1 includes a replacement nut and a 7. .CRIMP HEIGHT ADJUSTMENT (Figure 5) variety of pins, rings, screws, and springs. If the dies are damaged or worn excessively, they must be 1. Remove the lockscrew from the ratchet replaced. Order the repair kit and replaceable parts adjustment wheel. through your TE representative, or call 1-800-526- 2. With a screwdriver, adjust the ratchet wheel 5142, or send a facsimile of your purchase order to 1- from the locator side of the tool. 717-986-7605, or write to: 3. Observe the ratchet adjustment wheel. If a CUSTOMER SERVICE (038-035) tighter crimp is required, rotate the adjustment TYCO ELECTRONICS CORPORATION wheel COUNTERCLOCKWISE to a higher- PO BOX 3608 numbered setting. If a looser crimp is required, HARRISBURG PA 17105-3608 rotate the adjustment wheel CLOCKWISE to a lower-numbered setting. 11. REVISION SUMMARY 4. Replace the lockscrew. Since the previous release of this sheet, the following changes were made: 5. Make a sample crimp and measure the crimp height. If the dimension is acceptable, replace • Added new information to bottom of Figure 1 table and secure the lockscrew. If the dimension is and callout in Figure 2 unacceptable, continue to adjust the ratchet, and • Changed information on last page again measure a sample crimp. Rev F 4 of 5 408-4064 PRO-CRIMPER III Hand Tool Frame 354940-1 SDE-SA Hand Tool 9-1478240-0 (Instruction Sheet 408-9930) (Instruction Sheet 408-8851) Use Die Sets Use Die Sets 58517-2 or 58517-5 58517-4 SDE Bench Terminator 1490076-2 626 Adapter 679304-1 (Customer Manual 409-10052) (Instruction Sheet 408-4070) Use Die Set 58517-5 Use Die Set 58517-2 or 58517-4 Battery Tool (Shouldered Die) 1725837-1, -2 Battery Tool (Pin Die) 1213890-1, -2 (Customer Manual 409-10053) (Customer Manual 409-10065) Use Die Set 58517-5 Rev F 5 of 5