Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 58546-1 408-8678 and Die Assemblies 58545-[ ] 13 MAR 14 Rev E 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. PRO-CRIMPER III Hand Crimping Stationary Jaw Tool 58546-1 Shown Back of Tool (Wire Side) Front of Tool Pivot Pin Die Assembly 58545-1 PRO-CRIMPER III Hand Crimping Tool Frame 354940-1 (Instruction Moving Sheet 408-9930) Jaw Ratchet Adjustment Wheel Stationary Handle 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 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 Handle information, contact the Tooling Assistance Center at 1-800-722-1111. WIRE DIE PRODUCT FAMILY‡ STRIP LENGTH ASSEMBLY• (SOLISTRAND*) SIZE (AWG) (mm [in.]) Terminal (Standard) 22-14 4.37-5.16 [.172-.203] 58545-1 Terminal (Standard) and Butt Splice 12-10 6.35-7.14 [.250-.281] 58545-3 Terminal (Long Barrel) or Butt Splice 22-14 6.35-7.14 [.250-.281] 58545-4 Terminal Parallel Splice 22-14 7.94-8.73 [.312-.344] ‡Contact the Tooling Assistance Center or Product Information (at the number listed below) for specific terminal and splice part numbers. •See page 6 for die assembly cross reference. Figure 1 1. INTRODUCTION Specific part numbers for die set 58545-[ ] may be NOTE used with other optional crimp tooling. Refer to Die Assembly 58545-[ ] and PRO-CRIMPER III Hand Figure 7 for specific relationships. i Tool 58546-1 are used to crimp SOLISTRAND Terminals and Splices onto the wire size listed in Figure 1. PRO-CRIMPER III Hand Tool Assembly Dimensions in this instruction sheet are in metric NOTE consists of Hand Tool Frame 354940-1 and Die units [with U.S. customary units in brackets]. Assembly 58545-1. Figures and illustrations are for reference only and i Read these instructions thoroughly before using the are not drawn to scale. tool assembly. © 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 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 408-8678 Stationary Jaw Indenters Upper Die Die Retaining Screws Lower Die Anvils Figure 2 This document supersedes Instruction Sheet 6. Carefully close the tool handles, making sure that 408-4047. the anvils and indenters align properly. Continue closing the tool handles until the ratchet has Reasons for reissue of this instruction sheet are engaged sufficiently to hold the dies in place, then provided in Section 8, REVISION SUMMARY. tighten both die retaining screws. 7. To disassemble, open the tool handles until the 2. DESCRIPTION (See Figures 1 and 2) ratchet releases, remove the two die retaining The tool consist of a stationary jaw and handle, a screws, and slide the dies out of the tool jaws. moving jaw and handle, and an adjustable ratchet that ensures full crimping. 4. CRIMPING PROCEDURE The tool frame holds a die assembly with three Before using the tool, the crimping chambers and NOTE crimping chambers. The die assembly features an tool ratchet should be inspected as specified in upper die and a lower die. Die retaining screws are Section 5, CRIMP HEIGHT INSPECTION, and i used to position and secure the dies in the tool frame. Section 6, RATCHET (Shut Height) ADJUSTMENT. Refer to Figure 1 and select wire of the specified size 3. DIE ASSEMBLY INSTALLATION AND REMOVAL and insulation diameter. Strip the wire to the length 1. Open the tool handles and remove the two die indicated, taking care not to nick or cut wire strands. retaining screws from the tool jaws. Select an applicable terminal or splice and identify the appropriate crimping chamber according to the wire 2. Place the upper die in the stationary jaw of the size markings on the dies. Refer to Figure 3 and tool frame so that the largest indenter is facing proceed as follows: inward. See Figure 2. The crimping chamber marked “12-10” cannot be 3. Insert the die retaining screw through the NOTE used to crimp spade-type terminals. stationary jaw and through the die. Tighten the screw just enough to hold the die in place. Do not i tighten the screw completely at this time. 1. Hold tool so that the back (wire side) is facing 4. Place the lower die in the moving jaw of the tool you. Squeeze tool handles together until the ratchet frame so that the largest anvil is facing inward. See releases, then allow them to open fully. Figure 2. 2. Center the terminal or splice wire barrel on the 5. Insert the die retaining screw through the moving anvil of the upper die as shown in Figure 3. If jaw and through the die. Tighten the screw just visible, be sure to place the brazed seam on the enough to hold the die in place. Do not tighten the terminal or splice toward the indenter. screw completely at this time. Rev E 2 of 6 408-8678 hold the terminal or splice in position. Do NOT deform the insulation barrel or wire barrel. Terminal 4. Insert stripped wire into the wire barrel, making sure that the insulation does not enter the wire barrel. See Figure 3. 5. To crimp the other half of a splice, reposition the uncrimped wire barrel in the crimping chamber, and repeat the crimping procedure. 6. To crimp the other half of a splice, reposition the Terminal Wire Barrel uncrimped wire barrel in the crimping chamber, and Centered on Anvil of repeat the crimping procedure. Lower Die If splice cannot be turned for crimping the other NOTE half, turn the tool around. i 7. Inspect the crimped terminal or splice according Stripped Wire to Figure 4. Check the crimp height as described in Section 5. If necessary, adjust the ratchet (shut height) as described in Section 6. Splice Terminal Splice Wire Barrel Parallel Splice Centered on Anvil Butt Splice of Lower Die Brazed Seam Positioned Toward Indenter Inspection Hole Parallel Splice Splice Wire Barrel Centered on Anvil of Lower Die Figure 3 3. Hold the wire barrel in place and squeeze the tool handles together until ratchet engages sufficiently to Figure 4 Rev E 3 of 6 408-8678 Damaged terminals and splices may not be used. If 3. Align the GO element with the crimping chamber. CAUTION a damaged terminal or splice is evident, it must be Push element straight into the crimping chamber replaced with a new one. without using force. ! The GO element must pass completely through the NOTE crimping chamber. See Figure 5. 5. CRIMP HEIGHT INSPECTION i This inspection requires the use of plug gages conforming to the dimensions provided in Figure 5. TE 4. Align the NO-GO element and try to insert it does not manufacture or market these gages. straight into the same crimping chamber. The NO-GO element may start entry, but must not pass To gage the crimping chamber, proceed as follows: completely through the crimping chamber. See 1. Remove traces of oil or dirt from the crimping Figure 5. chamber and plug gage. If the crimping chamber conforms to the gage 2. Close the tool handles until the dies have inspection, the tool is considered dimensionally bottomed. Do NOT force dies beyond initial contact. correct, and should be lubricated with a THIN coat of any good SAE 20 motor oil. If not, the tool must be returned to TE for further evaluation and repair. Refer to Section 8, REPLACEMENT. for 58545-[ ] For additional information regarding the use of a plug gage, refer to Instruction Sheet 408-7424. 6. RATCHET (SHUT HEIGHT) ADJUSTMENT (Figure 6) The frame assembly ratchet mechanism features an adjustment wheel with numbered settings. If the dies do not bottom, adjust the ratchet as follows: 1. Remove the lockscrew from the ratchet adjustment wheel. 2. With a screwdriver, adjust the ratchet wheel from CRIMPING GAGE ELEMENT DIMENSIONS the opposite side of the frame. CHAMBER GO NO-GO “R” (RADIUS) (Die Marking) 3. Observe the ratchet adjustment wheel. If the dies 1.143-1.151 1.344-1.346 do not bottom, rotate the adjustment wheel 22-16 1.57 [.062] [.0450-.0453] [.0529-.0530] COUNTERCLOCKWISE to a higher-numbered setting. 1.346-1.354 1.547-1.549 16-14 1.98 [.078] [.0530-.0533] [.0609-.0610] 4. Replace the lockscrew. 1.905-1.913 2.106-1.108 12-10 2.77 [.109] [.0750-.0753] [.0829-.0830] Screwdriver GO Element Must Pass Completely Through Crimping Chamber Ratchet Adjustment Wheel Lockscrew NO-GO Element May Start Entry, But Must Not Pass Completely Through Crimping Chamber Figure 6 Figure 5 Rev E 4 of 6 408-8678 7. MAINTENANCE AND INSPECTION replacement nut and a variety of pins, rings, screws, and springs. 7.1. Maintenance If the dies are damaged or worn excessively, they Ensure that the tool and dies are clean by wiping them must be replaced. with a clean, soft cloth. Remove any debris with a Order the repair kit and replaceable parts through your clean, soft brush. Do not use objects that could TE Representative, or call 1-800-526-5142, or send a damage the tool. When not in use, keep handles facsimile of your purchase order to 717-986-7605, or closed to prevent objects from becoming lodged in the write to: crimping dies, and store in a clean, dry area. CUSTOMER SERVICE (038-035) 7.2. Visual Inspection TYCO ELECTRONICS CORPORATION The die assembly 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 crimping chambers for flattened, chipped, worn, or broken areas. If damage or abnormal wear is evident, the tool or dies must be For tool repair service, please contact a TE replaced. See Section 8, REPLACEMENT. Representative at 1-800-526-5136. 8. REPLACEMENT Customer-replaceable parts are shown in Figure 1. 9. REVISION SUMMARY Available separately, PRO-CRIMPER III Hand • Updated document to corporate requirements Crimping Tool Repair Kit 679221-1 includes a • Added clarifying note to table in Figure 1 Rev E 5 of 6 408-8678 Tooling Compatible with Die Assembly 58545-[ ] Die Assembly 58545-1 for PRO-CRIMPER III Die Assembly 58545-1 for SDE-SA Hand Tool Frame 354940-1 Hand Tool 9-1478240-0 (Instruction Sheet 408-9930) (Instruction Sheet 408-8851) Die Assembly 58545-3 for SDE Bench Die Assembly 58545-4 for 626 Terminator 1490076-2 Adapter 679304-1 (Customer Manual 409-10052) (Instruction Sheet 408-4070) Die Assembly 58545-3 for Electro-Hydraulic (BT 3500 Battery-Hydraulic) Hand Tool Kits 2031400-[ ] Closed Head Assembly 2031460-1 “C”-Head Assembly 2031450-1 (Customer Manual 409-10095) (Instruction Sheet 408-10312) (Instruction Sheet 408-10311) Figure 7 Rev E 6 of 6