Instruction Sheet PRO-CRIMPER*IIIHand CrimpingToolAssembly58529-1 408--9999 with DieAssembly58529-2 11 AUG 14 RevD 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 PRO--CRIMPER III Hand Assembly Crimping Tool Frame Moving Jaw 354940--1 (408--9930) Ratchet Adjustment Wheel Stationary The PRO--CRIMPER IIIHand Crimping Tool isa “Commercial”grade tool Handle and isdesigned primarilyforfield installation,repair,maintenance work,or prototyping in industrial,commercial,orinstitutional applications.Product crimped with thistool will meetthe crimp heightrequirementforhand toolsin Moving Handle the appropriate 114 seriesspecification,butmaynotcomplywith otherfeature parametersofthe specification.TEConnectivityoffersa 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 a c Size StripLength Assembly Assembly Family InsulDia (AWG) (mm[In.]) 16 A AM MPSE PSEA AL L* 1 1..7t 7 to2 o 2..7 7 5.15.1 5.15.1áá.4 .4 5 58 85 52 29 9----2 2 5 58 85 51 15 5----1 1 Contacts [.07to.11] [.20á.02] 18 to 20 a Supplied with the die assembly. Also available separately. c Call the Tooling Assistance Center or Production Information (see below) for product part numbers. Figure 1 Dimensions on this sheet are in millimeters [with 1. INTRODUCTION NOTE inch equivalents provided in brackets]. Figures PRO--CRIMPER III Hand Crimping Tool and illustrations are for identification only and are i Assembly 58529--1 consists of Die Assembly not drawn to scale. 58529--2 and PRO--CRIMPER III Hand Tool Frame 354940--1. The die assembly consists of crimping dies and a locator assembly. 2. DESCRIPTION (Figures1 and 2) Read these instructions thoroughly before crimping any contacts. The tool features a tool frame with a stationary jaw Reasons for reissue are provided in Section 11, and handle, a moving jaw, a moving handle, and an REVISION SUMMARY. adjustable ratchet that ensures full contact crimping. .2014 TE Connectivity family of companies 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 LOCB TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-9999 Locator Nut Assembly Tool Frame Locator Insulation Die Retaing Crimper Chamfer Pins Wire Crimper Offset Wire Anvil Chamfer Die Retaining Insulation Screws Anvil Figure 2 The tool frame holds a die assembly with two 5. Place the wire crimper and insulation crimper so crimping sections. that their chamfered sides and their marked 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. Die retaining pins and die retaining screws are used to position and secure the dies in the tool frame. A 8. Carefully close the tool handles, making sure nut is used on the upper die retaining screw to hold that the anvils and crimpers align properly. the locator assembly in place. 9. Continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to 3. INSTALLATIONANDREMOVALOFDIESET hold the anvils and crimpers in place, then tighten ANDLOCATORASSEMBLY (Figure 2) both die retaining screws. 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 face outward, when mounted in the moving jaw of and tighten the nut enough to hold the locator the tool frame. assembly 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 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. 2 of 6 Rev D 408-9999 contact is still being bent during crimping, repeat 4. CONTACTSUPPORTADJUSTMENT (Figure 3) 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 contact is straight, bending upward, or bending i Section 6, CRIMP HEIGHT INSPECTION, and downward. Section 7, RATCHET ADJUSTMENT, to verify 2. If adjustment is required, loosen the screw that crimp height before using the tool to crimp holds the contact support onto the locator desired contacts and wire sizes. assembly. Refer to the table in Figure 1 and select wire of the The ratchet has detents that create audible clicks NOTE specified size and insulation diameter. Strip the wire as the tool handles are closed. to the length indicated in Figure 1, taking care not to 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 3. Place a contact with wire into the proper nest Figure 3 and proceed as follows: 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 the contact. facing you. Squeeze tool handles together and allow them to open fully. 4. Slightly loosen the nut that holds the locator 2. Holding the contact by the mating end, insert the assembly onto the tool frame. contact — insulation barrel first — through the front 5. Move the contact support as required to of the tool and into the appropriate crimp section. eliminate the bending of the contact. 3. Position the contact so that the mating end of 6. Tighten the nut and close the handles until the the contact is on the locator side of the tool, and so ratchet releases. that the open “U” of the wire and insulation barrels face the top of the tool. Place the contact up into 7. Remove and inspect the contact. the nest so that the movable locator drops into the 8. Make another sample crimp. If the contact is slot in the contact. Refer to Figure 3. Butt the front straight, tighten the contact support screw. If the end of the wire barrel against the movable locator. Contact Locator Support Back of Tool Adjustment (Wire Side) Screw for Contact Support Contact Strip (Typ) Length Locator Wire in Wire Wire Slot Inserted to Stop Figure 3 Rev D 3 of 6 408-9999 Make sure that both sides of the insulation barrel Proceed as follows: CAUTION are started evenly into the crimping section. Do 1. Refer to Figure 4 and select a wire (maximum NOT attempt to crimp an improperly positioned ! size) for each crimp section listed. contact. 2. Refer to Section 5, CRIMPING PROCEDURE, 4. Hold the contact in position and squeeze the and crimp the contact(s) accordingly. tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT 3. Using a crimp height comparator, measure the deform insulation barrel or wire barrel. wire barrel crimp height as shown in Figure 4. If the crimp height conforms to that shown in the table, 5. Insert stripped wire into contact insulation and the tool is considered dimensionally correct. If not, wire barrels until it is butted against the wire stop, the tool must be adjusted. Refer to Section 7, as shown in Figure 3. RATCHET ADJUSTMENT. 6. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles 7. RATCHET(CrimpHeight)ADJUSTMENT (Figure 5) to open and remove crimped contact. 1. Remove the lockscrew from the ratchet adjustment wheel. The crimped contact may stick in the crimping NOTE area, but the contact can be easily removed by 2. With a screwdriver, adjust the ratchet wheel pushing downward on the top of the locator (see i from the locator side of the tool. Figure 3). 3. Observe the ratchet adjustment wheel. If a 7. Check the contact’s crimp height as described in tighter crimp is required, rotate the adjustment Section 6, CRIMP HEIGHT INSPECTION. If wheel COUNTERCLOCKWISE to a necessary, adjust the crimp height as described in higher--numbered setting. If a looser crimp is Section 7, RATCHET ADJUSTMENT. required, rotate the adjustment wheel CLOCKWISE to a lower--numbered setting. 4. Replace the lockscrew. 6. CRIMPHEIGHTINSPECTION 5. Make a sample crimp and measure the crimp Crimp height inspection is performed through the use height. If the dimension is acceptable, replace and of a micrometer with a modified anvil, commonly secure the lockscrew. If the dimension is referred to as a crimp--height comparator. TE does unacceptable, continue to adjust the ratchet, and not manufacture or market crimp--height comparators. again measure a sample crimp. Detailed information on obtaining and using crimp--height comparators can be found in instruction sheet 408--7424. Screwdriver Position Point on Center of Wire Barrel Opposite Seam Modified Anvil “A” Ratchet Adjustment Wir WireeS Siz izee Cri Crim mp pS Seect ctiio on n Cri Crim mp pHe Heiig ght ht Wheel AWG (Max) (WireSize Marking) DimensionA 1.22á.05 18 20--18 [.048á.002] 1.41á.05 16 16 Lockscrew [.056á.002] (Typ) Figure 4 Figure 5 4 of 6 Rev D 408-9999 Available separately, PRO--CRIMPER III Hand 8. MAINTENANCE Crimping Tool Repair Kit 679221--1 includes a Ensure that the tool and dies are clean by wiping replacement nut and a variety of pins, rings, screws, them with a clean, soft cloth. Remove any debris with and springs. a clean, soft brush. Do not use objects that could damage the tool. When not in use, keep handles If the dies are damaged or worn excessively, they closed to prevent objects from becoming lodged in must be replaced. the crimping dies, and store in a clean, dry area. Order the repair kit and replaceable parts through your TE representative, or call 1--800--526--5142, or send a facsimile of your purchase order to 9. VISUALINSPECTION 1--717--986--7605, or write to: The crimping dies should be inspected on a regular CUSTOMER SERVICE (38--35) basis to ensure that they have not become worn or TYCO ELECTRONICS damaged. Inspect the crimp sections for flattened, PO BOX 3608 chipped, worn, or broken areas. If damage or HARRISBURG PA 17105--3608 abnormal wear is evident, the tool must be replaced. See Section 10, REPLACEMENT. 11.REVISIONSUMMARY 10. REPLACEMENT Revisions to this instruction sheet include: : Changed wire size in table in Figure 1 Customer--replaceable parts are shown in Figure 1. Rev D 5 of 6 408-9999 DieAssembly58529-2CanBeUsedIntheFollowingTools: 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 Rev D