Instruction Sheet PRO-CRIMPER*IIIHand CrimpingToolAssembly58528-1 408--9997 withDieAssembly58528-2 03 SEP 09 RevB 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 (Locator Side) Pivot Pin Die PRO--CRIMPER III Hand Assembly Crimping Tool Frame 354940--1 (408--9930) Moving Jaw Ratchet Adjustment Wheel The PRO--CRIMPER IIIHand Crimping Tool isa “Commercial”grade tool Stationary 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 Moving Handle parametersofthe specification.Tyco Electronics offersa varietyoftoolsto satisfyyourperformance requirements.Foradditional information,contactthe 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.]) 1.40 to 1.78 24 [.055 to .070] .070 .070S Se erriies es 3.48 3.48 tto o3.99 3.99 5 58 85 52 28 8----2 2 5 58 85 51 16 6----1 1 Contacts [.137 to .157] 1.40 to 1.88 22 [.055 to .074] { Supplied with the die assembly. Also available separately. } Callthe 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 58528--1 consists of Die Assembly 58528--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. 408-9997 PRO-CRIMPERIIIHandCrimpingToolAssembly58528-1 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 (Figure 1 and Figure 2) 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 two 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. INSTALLATIONANDREMOVALOFDIESET against the side of the tool jaw. ANDLOCATORASSEMBLY (Figure 2) 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 RevB 408-9997 PRO-CRIMPERIIIHandCrimpingToolAssembly58528-1 4. CONTACTSUPPORTADJUSTMENT (Figure 3) 5. CRIMPINGPROCEDURE This tool is provided with a crimp adjustment NOTE The contact support is preset prior to shipment, NOTE feature. Initially, the crimp height should be but minor adjustment may be necessary. verified as specified in Figure 4. Refer to i i Section 6, CRIMP HEIGHT INSPECTION, and Section 7, RATCHET (Crimp Height) ADJUSTMENT, to verify crimp height before 1. Make a sample crimp and determine if the using the tool to crimp desired contacts and wire contact is straight, bending upward, or bending sizes. downward. Refer to the table in Figure 1 and select wire of the 2. If adjustment is required, loosen the screw that specified size and insulation diameter. Strip the wire holds the contact support onto the locator to the length indicated in Figure 1, taking care not to assembly. nick or cut wire strands. Select an applicable contact The ratchet has detents that create audible clicks and identify the appropriate crimp section according NOTE as the tool handles are closed. to the wire size markings on the tool. Refer to Figure 3 and proceed as follows: i 1. Hold the tool so that the back (wire side) is facing you. Squeeze tool handles together and 3. Place a contact with wire into the proper nest allow them to open fully and close the tool handles until the ratchet reaches the sixth click, or until the contact support touches 2. Holding the contact by the mating end, insert the the contact. contact — insulation barrel first — through the front of the tool and into the appropriate crimp section. 4. Slightly loosen the nut that holds the locator assembly onto the tool frame. 3. Position the contact so that the mating end of the contact is on the locator side of the tool, and so 5. Move the contact support as required to that the open “U” of the wire and insulation barrels eliminate the bending of the contact. face the top of the tool. Place the contact up into the nest so that the movable locator drops into the 6. Tighten the nut and close the handles until the slot in the contact. Refer to Figure 3. Butt the front ratchet releases. end of the wire barrel against the movable locator. 7. Remove and inspect the contact. Make sure that both sides of the insulation barrel CAUTION 8. Make another sample crimp. If the contact is are started evenly into the crimping section. Do straight, tighten the contact support screw. If the NOT attempt to crimp an improperly positioned ! contact is still being bent during crimping, repeat contact. the adjustment procedure. Locator Contact Support Back of Tool (Wire Side) Adjustment Contact Screw for (Typ) Strip Contact Length Support Locator in Wire Wire Stop Slot Wire Inserted to Stop Figure 3 RevB Tyco ElectronicsCorporation 3 of 6 408-9997 PRO-CRIMPERIIIHandCrimpingToolAssembly58528-1 Position Point 4. Hold the contact in position and squeeze the on Center of tool handles together until ratchet engages Wire Barrel sufficiently to hold the contact in position. Do NOT Opposite deform insulation barrel or wire barrel. Seam 5. Insert stripped wire into contact insulation and wire barrels until it is butted against the wire stop, as shown in Figure 3. Modified Anvil “A” 6. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles CrimpHeight to open and remove crimped contact. Wir WireeS Siz izee Cri Crim mp pS Seect ctiio on n D Diim mA Aaan nd d AWG (Max) (WireSizeMarking) Tolerance[+]) The crimped contact may stick in the crimping NOTE area, but the contact can be easily removed by .889.051 24 24 [.0350.0020] pushing downward on the top of the locator (see i Figure 3). .940.051 22 22 [.0370.0020] 7. Check the contact’s crimp height as described in Section 6, CRIMP HEIGHT INSPECTION. If Figure 4 necessary, adjust the crimp height as described in Section 7, RATCHET (Crimp Height) 4. Replace the lockscrew. ADJUSTMENT. 5. Make a sample crimp and measure the crimp 6. CRIMPHEIGHTINSPECTION height. If the dimension is acceptable, replace and 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 8. MAINTENANCE crimp--height comparators. Detailed information on obtaining and using crimp--height comparators can be Ensure that the tool and dies are clean by wiping found in instruction sheet 408--7424. them with a clean, soft cloth. Remove any debris with a clean, soft brush. Do not use objects that could Proceed as follows: damage the tool. When not in use, keep handles 1. Refer to Figure 4 and select a wire (maximum closed to prevent objects from becoming lodged in size) for each crimp section listed. the crimping dies, and store in a clean, dry area. 2. Refer to Section 5, CRIMPING PROCEDURE, and crimp the contact(s) accordingly. Screwdriver 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, the tool must be adjusted. Refer to Section 7, RATCHET (Crimp Height) ADJUSTMENT. 7. RATCHET(CrimpHeight)ADJUSTMENT (Figure 5) 1. Remove the lockscrew from the ratchet Ratchet adjustment wheel. Adjustment Wheel 2. With a screwdriver, adjust the ratchet wheel from the locator side of the tool. 3. Observe the ratchet adjustment wheel. If a Lockscrew tighter crimp is required, rotate the adjustment (Typ) wheel COUNTERCLOCKWISE to a higher--numbered setting. If a looser crimp is required, rotate the adjustment wheel Figure 5 CLOCKWISE to a lower--numbered setting. 4 of 6 Tyco ElectronicsCorporation RevB 408-9997 PRO-CRIMPERIIIHandCrimpingToolAssembly58528-1 9. VISUALINSPECTION 11.REVISIONSUMMARY The crimping dies should be inspected on a regular Revisions to this instruction sheet include: basis to ensure that they have not become worn or S Changed PRO--CRIMPER II Hand Tool to damaged. Inspect the crimp sections for flattened, PRO--CRIMPER III Hand Tool; chipped, worn, or broken areas. If damage or S Revised information in the crimp height abnormal wear is evident, the tool must be replaced. inspection section; See Section 10, REPLACEMENT. S Added the TE logo; 10. REPLACEMENT S Updated format; and Customer--replaceable parts are shown in Figure 1. S Added back page showing tooling compatible with die set 58528--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. CUSTOMER SERVICE (38--35) TYCO ELECTRONICS PO BOX 3608 HARRISBURG PA 17105--3608 RevB Tyco ElectronicsCorporation 5 of 6 408-9997 PRO-CRIMPERIIIHandCrimpingToolAssembly58528-1 DieAssembly58528-2CanBeUsedIntheFollowingTools: 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 RevB