Instruction Sheet PRO-CRIMPER*IIIHandCrimping ToolAssembly58535-1with 408--4021 DieAssembly58535-2 29 JUL 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 (Lower Side) Pivot Pin PRO--CRIMPER III Die Hand Crimping Tool Assembly Frame 345940--1 Moving Jaw (408--9930) Ratchet Adjustment Stationary Wheel Handle The PRO--CRIMPER IIIHand Crimping Tool Assemblyisa “Commercial” grade tool and isdesigned primarilyforfield installation,repair,maintenance work,orprototyping in industrial,commercial,orinstitutional applications. Moving Handle Productcrimped with thistool will meetthe crimp heightrequirementforhand toolsin the appropriate 114 seriesspecification,butmaynotcomplywith other feature parametersofthe specification.Tyco Electronicsoffersa varietyof toolsto satisfyyourperformance requirements.Foradditional information, contactthe Technical Assistance Centerat1--800--722--1111. Wire C Co on nttaacctt {{ TEDieAssembly LocatorAssembly } Size Ins.Dia. StripLength Family (AWG) (mm[In.]) (mm[In.]) FFC Round Wire 1.0to1.4 2.8to3.6 58535--2 58516--1 Pin and Receptacle 26--22 [.040 to .056] .110 to .140 Contacts } Supplied with Die Assembly.. Also Available separately. } Contactthe Technical Assistance Center or ProductInformation (see below) for specificcontactpartnumbers. Figure 1 Dimensions on this sheet are in millimeters [with 1. INTRODUCTION NOTE inch equivalents provided in brackets]. Figures and illustrations are for identification only and are i PRO--CRIMPER III Hand Crimping Tool not drawn to scale. Assembly 58535--1 consists of Die Assembly Reasons for reissue are provided in Section 11, 58535--2 and PRO--CRIMPER III Hand Crimping Tool REVISION SUMMARY. 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 The tool features a tool frame with a stationary jaw any contacts. and handle, a moving jaw, a moving handle, and an 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. 408-4021 PRO-CRIMPERIIIHandCrimpingToolAssembly58535-1 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 stationary jaw of the tool frame. The die assembly features a wire anvil, an insulation 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. Continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold the anvils and crimpers in place, then tighten both 3. INSTALLATIONANDREMOVALOFDIESET die retaining screws. ANDLOCATORASSEMBLY (Figure 2) 9. Place the locator assembly over the end of the 1. Open the tool handles and remove the two die long screw, and position the locator assembly retaining screws from the tool jaws. against the side of the tool jaw. 2. Place the wire anvil and insulation anvil so that 10. Place the nut onto the end of the long screw their chamfered sides and their marked surfaces and tighten the nut enough to hold the locator face outward, when mounted in the moving jaw of assembly in place, while still allowing the locator to the tool frame. slide up and down. 3. Insert the two die retaining pins. 11. 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. Nut Locator Assembly Tool Frame Locator Die Retaining Insulation Pins Crimper Chamfer Wire Crimper Offset Wire Anvil Chamfer Insulation Die Retaing Screws Anvil Figure 2 2 of 6 Tyco ElectronicsCorporation RevC 408-4021 PRO-CRIMPERIIIHandCrimpingToolAssembly58535-1 4. CONTACTSUPPORTADJUSTMENT (Figure 3) 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 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 Contact (Wire Side) Strip Length Adjustment Screw for Contact Wire Support Stabilizer Barrel (Not Crimped) Locator in Wire Wire Inserted Stop Slot to Stop Figure 3 RevC Tyco ElectronicsCorporation 3 of 6 408-4021 PRO-CRIMPERIIIHandCrimpingToolAssembly58535-1 Make sure that both sides of the insulation barrel Position CAUTION are started evenly into the crimping section. Do Point on Center of NOT attempt to crimp an improperly positioned ! Wire Barrel contact. Opposite Seam 4. Hold the contact in position and squeeze the tool handles together until the ratchet engages sufficiently to hold the contact in position. Do NOT “A” Modified deform insulation barrel or wire barrel. Anvil 5. Insert stripped wire into contact insulation and wire barrels until it is butted against the wire stop, CrimpHeight as shown in Figure 3. WireSize CrimpSection Dim.“A”and Tolerance (+) AWG (Max) (WireSizeMarking) 6. Holding the wire in place, squeeze tool handles (mm[In.]) together until ratchet releases. Allow tool handles to open and remove crimped contact. .71 .05 22 22 [.028 002] The crimped contact may stick in the crimping NOTE .64 .05 area, but the contact can be easily removed by 24 26--24 [.025.002] pushing downward on the top of the locator (see i Figure 3). Figure 4 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. 6. CRIMPHEIGHTINSPECTION 4. Replace the lockscrew. Crimp height inspection is performed through the use 5. Make a sample crimp and measure the crimp of a micrometer with a modified anvil, commonly height. If the dimension is acceptable, replace and referred to as a crimp--height comparator. Tyco secure the lockscrew. If the dimension is Electronics does not manufacture or market unacceptable, continue to adjust the ratchet, and crimp--height comparators. Detailed information on again measure a sample crimp. obtaining and using crimp--height comparators can be found in instruction sheet 408--7424. Screwdriver 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. 3. Using a crimp height comparator, measure the wire barrel crimp height as shown in Figure 4. If the Ratchet crimp height conforms to that shown in the table, Adjustment the tool is considered dimensionally correct. If not, Wheel the tool must be adjusted. Refer to Section 7, RATCHET ADJUSTMENT. 7. RATCHET(CrimpHeight)ADJUSTMENT (Figure 5) Lockscrew 1. Remove the lockscrew from the ratchet adjustment wheel. Figure5 2. With a screwdriver, adjust the ratchet wheel from the locator side of the tool. 4 of 6 Tyco ElectronicsCorporation RevC 408-4021 PRO-CRIMPERIIIHandCrimpingToolAssembly58535-1 8. MAINTENANCE replacement nut and a variety of pins, rings, screws, and springs. Ensure that the tool and dies are clean by wiping If the dies are damaged or worn excessively, they them with a clean, soft cloth. Remove any debris with must be replaced. a clean, soft brush. Do not use objects that could damage the tool. When not in use, keep handles Order the repair kit and replaceable parts through closed to prevent objects from becoming lodged in your Tyco Electronics representative, or call the crimping dies, and store in a clean, dry area. 1--800--526--5142, or send a facsimile of your purchase order to 1--717--986--7605, or write to: 9. VISUALINSPECTION CUSTOMER SERVICE (38--35) TYCO ELECTRONICS CORPORATION The crimping dies should be inspected on a regular PO BOX 3608 basis to ensure that they have not become worn or HARRISBURG PA 17105--3608 damaged. Inspect the crimp sections for flattened, chipped, worn, or broken areas. If damage or abnormal wear is evident, the tool must be replaced. 11.REVISIONSUMMARY See Section 10, REPLACEMENT. Revisions to this instruction sheet include: S Revision to figure 3 to illustrate the contact 10. REPLACEMENT stabilizer; and S Addition of back page, indicating tooling that Customer--replaceable parts are shown in Figure 1. will handle die 58535--2. Available separately, PRO--CRIMPER III Hand Crimping Tool Repair Kit 679221--1 includes a RevC Tyco ElectronicsCorporation 5 of 6 408-4021 PRO-CRIMPERIIIHandCrimpingToolAssembly58535-1 DieAssembly58535-2CanBeUsedIntheFollowingTools: 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