Instruction Sheet PRO-CRIMPER*IIIHandCrimping ToolAssembly58522-1with 408--9996 DieAssembly58522-2 08SEP 09 RevC PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awide selection ofpowered application equipmentforextended--use,production operationsisavailable. Locator Assembly Stationary Jaw (Supplied with Back of Tool Die Assembly) Wire Side) Front of Tool Pivot Pin (Locator Side) Die Assembly PRO--CRIMPER III Hand Crimping Tool Frame Moving Jaw 354940--1 (408--9930) Ratchet Adjustment Wheel Stationary The PRO--CRIMPER IIIHand Crimping Tool isa “Commercial”grade tool and isdesigned primarilyforfield installation,repair,maintenance work,or Handle prototyping in industrial,commercial,orinstitutional applications.Product crimped with thistool will meetthe crimp heightrequirementforhand toolsin the appropriate 114 seriesspecification,butmaynotcomplywith otherfeature parametersofthe specification.Tyco Electronics offersa varietyoftoolsto satisfyyourperformance requirements.Foradditional information,contactthe Moving Handle Tooling Assistance Centerat1--800--722--1111. Wire T TE ED Diiee T TE EL Lo occaatto orr C Co on nttaacctt { } Size StripLength Assembly Assembly Family InsulDia (AWG) (mm[In.]) 1.50to1.78 22 [.059to.070] .040 .040S Se erriies es 3.99 3.99 tto o4.50 4.50 5 58 85 52 22 2----2 2 5 58 85 51 16 6----1 1 Contacts [.157to1.77] 1.68to1.98 20 [.066to.078] { SUPPLIED WITH THE DIE ASSEMBLY. ALSO AVAILABLE SEPARATELY. } CALL THE TOOLING ASSISTANCE CENTER OR PRODUCT INFORMATION (SEE BELOW) FOR PRODUCT PART NUMBERS. Figure 1 any contacts. 1. INTRODUCTION Reasons for reissue are provided in Section 11, PRO--CRIMPER III Hand Crimping Tool REVISION SUMMARY. Assembly 58522--1 consists of Die Assembly 58522--2 and PRO--CRIMPER III Hand Crimping Tool Dimensions on this sheet are in millimeters [with NOTE Frame 354940--1. The die assembly consists of inch equivalents provided in brackets]. Figures crimping dies and a locator assembly. and illustrations are for identification only and are i Read these instructions thoroughly before crimping not drawn to scale. E2009 Tyco Electronics Corporation, Harrisburg, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlled document is subject to change. 1 of 6 PRODUCT INFORMATION1--800--522--6752 Forlatest revision and Regional CustomerService, All International Rights Reserved visit ourwebsite atwww.tycoelectronics.com TE logo and Tyco Electronics are trademarks. LOCB *Trademark. Otherproducts, logos, and company names used are the property of theirrespective owners. 408-9996 PRO-CRIMPERIIIHandCrimpingToolAssembly58522-1 Nut Locator Assembly Tool Frame Hold--Down Insulation Die Retaining Crimper Chamfer Pins Wire Crimper Offset Wire Anvil Chamfer Insulation Die Retaining Anvil Screws Figure 2 4. Insert the short die retaining screw through the 2. DESCRIPTION (Figures1and2) jaw and through both anvil dies, and tighten the The tool features a tool frame with a stationary jaw screw just enough to hold the dies in place. Do not and handle, a moving jaw, a moving handle, and an tighten the screw completely at this time. adjustable ratchet that ensures full contact crimping. 5. Place the wire crimper and insulation crimper so The tool frame holds a die assembly with three that their chamfered sides and their marked crimping sections. surfaces face outward, when mounted in the The die assembly features a wire anvil, an insulation stationary jaw of the tool frame. anvil, a wire crimper, and an insulation crimper. 6. Insert the two die retaining pins. Attached to the outside of the frame is a locator 7. Insert the long die retaining screw through the assembly, which contains a locator, a spring retainer, jaw and through both crimper dies, and tighten the and a contact support. screw just enough to hold the dies in place. Do not tighten the screw completely at this time. Attached to the opposite side of the frame is a hold--down, which locates the wire in the correct 8. Carefully close the tool handles, making sure position before crimping. that the anvils and crimpers align properly. Continue closing the tool handles until the ratchet Die retaining pins and die retaining screws are used in the tool frame has engaged sufficiently to hold to position and secure the dies in the tool frame. A the anvils and crimpers in place, then tighten both nut is used on the upper die retaining screw to hold die retaining screws. the locator assembly in place. 9. Place the locator assembly over the end of the long screw, and position the locator assembly 3. INSTALLATIONANDREMOVALOFDIESETAND against the side of the tool jaw. LOCATORASSEMBLY (Figure2) 10. Place the nut onto the end of the long screw and tighten the nut enough to hold the locator 1. Open the tool handles and remove the two die retaining screws from the tool jaws. assembly in place, while still allowing the locator to slide up and down. 2. Place the wire anvil and insulation anvil so that 11. To disassemble, close the tool handles until the their chamfered sides and their marked surfaces ratchet releases, remove the nut, the locator face outward, when mounted in the moving jaw of assembly, the two die retaining screws, and the the tool frame. four die retaining pins, and slide the anvils and 3. Insert the two die retaining pins. crimpers out of the tool jaws. 2 of 6 Tyco ElectronicsCorporation RevC 408-9996 PRO-CRIMPERIIIHandCrimpingToolAssembly58522-1 4. CONTACTSUPPORTADJUSTMENT (Figure3) contact is still being bent during crimping, repeat the adjustment procedure. The contact support is preset prior to shipment, NOTE but minor adjustment may be necessary. 5. CRIMPINGPROCEDURE i This tool is provided with a crimp adjustment NOTE feature. Initially, the crimp height should be 1. Make a sample crimp and determine if the verified as specified in Figure 4. Refer to Section contact is straight, bending upward, or bending i 6, CRIMP HEIGHT INSPECTION, and Section 7, downward. RATCHET ADJUSTMENT, to verify crimp height before using the tool to crimp desired contacts 2. If adjustment is required, loosen the screw that and wire sizes. holds the contact support onto the locator assembly. Refer to the table in Figure 1 and select wire of the specified size and insulation diameter. Strip the wire The ratchet has detents that create audible clicks NOTE to the length indicated in Figure 1, taking care not to as the tool handles are closed. nick or cut wire strands. Select an applicable contact i and identify the appropriate crimp section according to the wire size markings on the tool. Refer to Figure 3 and proceed as follows: 3. Place a contact with wire into the proper nest and close the tool handles until the ratchet reaches 1. Hold the tool so that the back (wire side) is the sixth click, or until the contact support touches facing you. Squeeze tool handles together and the contact. allow them to open fully. 4. Slightly loosen the nut that holds the locator 2. Position the contact so that the mating end of assembly onto the tool frame. the contact is on the locator side of the tool, and so that the open “U” of the wire and insulation barrels 5. Move the contact support as required to must face the top of the tool. Place the contact up eliminate the bending of the contact. into the nest so that the movable locator drops into the slot in the contact. Refer to Figure 3. Butt the 6. Tighten the nut and close the handles until the front end of the wire barrel against the movable ratchet releases. locator. 7. Remove and inspect the contact. 3. Holding the contact by the mating end, insert the 8. Make another sample crimp. If the contact is contact — insulation barrel first — through the front straight, tighten the contact support screw. If the of the tool and into the appropriate crimp section. Contact Locator Support Back of Tool (Wire Side) Adjustment Contact Screw for Strip (Typ) Contact Length Support Locator in Wire Wire Wire Inserted Stop Slot to Stop Figure 3 RevC Tyco ElectronicsCorporation 3 of 6 408-9996 PRO-CRIMPERIIIHandCrimpingToolAssembly58522-1 Position Point Make sure that both sides of the insulation barrel CAUTION on Center of are started evenly into the crimping section. Do Wire Barrel NOT attempt to crimp an improperly positioned ! Opposite contact. Seam 4. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT Modified Anvil “A” deform insulation barrel or wire barrel. CRIMPHEIGHT 5. Insert stripped wire into contact insulation and WIR WIRE ES SIZE IZE CRI CRIM MP PS SE EC CT TIIO ON N D DIIM ME EN NS SIIO ON NA A wire barrels until it is butted against the wire stop, AWG (Max) (ColorMarking) (+0.05[+.002]) as shown in Figure 3. .818 .081 22 22 6. Holding the wire in place, squeeze tool handles [.0322 .0032] together until ratchet releases. Allow tool handles .983. 084 to open and remove crimped contact. 20 20 [.0387 .0033] The crimped contact may stick in the crimping NOTE Figure 4 area, but the contact can be easily removed by pushing downward on the top of the locator (see i 3. Observe the ratchet adjustment wheel. If a Figure 3). tighter crimp is required, rotate the adjustment wheel COUNTERCLOCKWISE to a 7. Check the contact’s crimp height as described in higher--numbered setting. If a looser crimp is Section 6, CRIMP HEIGHT INSPECTION. If required, rotate the adjustment wheel necessary, adjust the crimp height as described in CLOCKWISE to a lower--numbered setting. Section 7, RATCHET (Crimp Height) ADJUSTMENT. 4. Replace the lockscrew. 5. Make a sample crimp and measure the crimp height. If the dimension is acceptable, replace and 6. CRIMPHEIGHTINSPECTION secure the lockscrew. If the dimension is Crimp height inspection is performed through the use unacceptable, continue to adjust the ratchet, and of a micrometer with a modified anvil, commonly again measure a sample crimp. referred to as a crimp--height comparator. Tyco Electronics does not manufacture or market crimp--height comparators. Detailed information on Screwdriver obtaining and using crimp--height comparators can be found in instruction sheet 408--7424. Proceed as follows: 1. Refer to Figure 4 and select a wire (maximum size) for each crimp section listed. 2. Refer to Section 5, CRIMPING PROCEDURE, and crimp the contact(s) accordingly. Ratchet 3. Using a crimp height comparator, measure the Adjustment wire barrel crimp height as shown in Figure 4. If the Wheel crimp height conforms to that shown in the table, the tool is considered dimensionally correct. If not, the tool must be adjusted. Refer to Section 7, CRIMP HEIGHT ADJUSTMENT. Lockscrew (Typ) 7. RATCHET(CrimpHeight)Adjustment (Figure5) 1. Remove the lockscrew from the ratchet adjustment wheel. Figure 5 2. With a screwdriver, adjust the ratchet wheel from the locator side of the tool. 4 of 6 Tyco ElectronicsCorporation RevC 408-9996 PRO-CRIMPERIIIHandCrimpingToolAssembly58522-1 8. MAINTENANCE Order the repair kit and replaceable parts through your Tyco Electronics representative, or call Ensure that the tool and dies are clean by wiping 1--800--526--5142, or send a facsimile of your them with a clean, soft cloth. Remove any debris with purchase order to 1--717--986--7605, or write to: a clean, soft brush. Do not use objects that could damage the tool. When not in use, keep handles CUSTOMER SERVICE (38--35) closed to prevent objects from becoming lodged in TYCO ELECTRONICS the crimping dies, and store in a clean, dry area. PO BOX 3608 HARRISBURG PA 17105--3608 9. VISUALINSPECTION 11.REVISIONSUMMARY The crimping dies should be inspected on a regular basis to ensure that they have not become worn or Revisions to this instruction sheet include: damaged. Inspect the crimp sections for flattened, S Changed PRO--CRIMPER II Hand Tool to chipped, worn, or broken areas. If damage or PRO--CRIMPER III Hand Tool; abnormal wear is evident, the tool must be replaced. See Section 10, REPLACEMENT. S Updated crimp--height inspection information; S Applied TE logo; S Updated format to current corporate 10. REPLACEMENT requirements; and S Added back page, indicating other tooling Customer--replaceable parts are shown in Figure 1. available for die assembly 58522--2. Available separately, PRO--CRIMPER III Hand Crimping Tool Repair Kit 679221--1 includes a replacement nut and a variety of pins, rings, screws, and springs. If the dies are damaged or worn excessively, they must be replaced. RevC Tyco ElectronicsCorporation 5 of 6 408-9996 PRO-CRIMPERIIIHandCrimpingToolAssembly58522-1 DieAssembly58522-2CanBeUsedIntheFollowingTools: 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) 6 of 6 Tyco ElectronicsCorporation RevC