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"!"*7-;269270885$2<*C866.;,2*50;*-.=885*7- 8?270 2<-.<207.-9;26*;25B/8;/2.5-27<=*55*=287;.9*2;6*27=.7*7,.@8;48; *7-5. 9;8=8=B92702727-><=;2*5,866.;,2*58;27<=2=>=287*5*9952,*=287,= ,;269.-@2=1=12<=885@2556..==1.,;2691.201=;.:>2;.6.7=/8;1*7-=885<27 =1.*99;89;2*=.*9952,*=287<9.,2/2,*=287+>=6*B78=,8695B@2=18=1.; /.*=>;.9*;*6.=.;<8/=1.<9.,2/2,*=287B,8$5.,=;872,;9.;/8;6*7,.;.:>2;.6.7=<8;*--2=287*527/8;6*=287 ,87=*,==1.885270$<<2<=*7,..7=.;*= .-2#%2 -13+#2*.- *6’20*/’-(2) *’11’,$+5.%#2.011’,$+5#,*+5 *#,’2’0 ,,,,!-%)’1" ,,!-%)’1" #%!"# #.;2.<87=*,=<())( 87=*,==1.885270$<<2<=*7,..7=.;8;!;8->,=7/8;6*=287.7=.; #>9952.-@2=1-2.*<<.6+5B*5<8*?*25*+5.<.9*;*=.5B +.58@/8;<9.,2/2,,87=*,=9*;=7>6+.;< Figure 1 Read these instructions thoroughly before crimping any contacts. PRO–CRIMPER III Hand Crimping Tool Assembly 58583–1 consists of Die Assembly 58583–2 and PRO–CRIMPER III Hand Crimping Tool Frame 354940–1. The die assembly consists of crimping dies and a locator assembly. $###$$"$12<,87=;855.--8,>6.7=2<<>+3.,==8,1*70.B,8$5.,=;872,<8;98;*=287*;;2<+>;0!8/ 557=.;7*=287*5"201=<".<.;?.-!" %$$ "8;5*=.<=;.?2<287*7-".0287*5><=86.;#.;?2,. $5808*7-B,8$5.,=;872,<*;.=;*-.6*;4;@.+<2=.*=25%.’+’%20.-*%1%.,444 ;*-.6*;4$ =1.;9;8->,=<5808<*7-,869*7B7*6.<><.-*;.=1.9;89.;=B8/=1.2;;.<9.,=2?.8@7.;< *0’ & )#%(#&"’’$**!%$+ !%!# &% $$) !!# !%!# % $ $&%! #"# # # #"# $% # ’ $&%! #% ’ #($ Figure 2 &#$ 4. Insert the short die retaining screw through the 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 chambers. The die assembly features a wire surfaces face outward, when mounted in the anvil, an insulation anvil, a wire crimper, and an stationary jaw of the tool frame. 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 8. Carefully close the tool handles, making sure to position and secure the dies in the tool frame. A that the anvils and crimpers align properly. nut is used on the upper die retaining screw to hold Continue closing the tool handles until the ratchet the locator assembly in place. in the tool frame has engaged sufficiently to hold the anvils and crimpers in place, then tighten both die retaining screws. &# 9. Place the locator assembly over the end of the long screw, and position the locator assembly 1. Open the tool handles and remove the two die against the side of the tool jaw. retaining screws from the tool jaws. 10. Place the nut onto the end of the long screw 2. Place the wire anvil and insulation anvil so that and tighten the nut enough to hold the locator their chamfered sides and their marked surfaces assembly in place, while still allowing the locator to face outward, when mounted in the moving jaw of slide up and down. the tool frame. 11. To disassemble, close the tool handles until the 3. Insert the two die retaining pins. ratchet releases, remove the nut, the locator !)!%#! $!#"!#%! ’ #& "% #$$!’’"!( assembly, the two die retaining screws, and the 8. Make another sample crimp. If the contact is four die retaining pins, and slide the anvils and straight, tighten the contact support screw. If the crimpers out of the tool jaws. contact is still being bent during crimping, repeat the adjustment procedure. # &%**)+’’&(* )’()*’( &(*&) ’$%* )*&&# )’(&, - *( $’!+)*$%* +*$ %&(!+)*$%*$.%))(. *+(% * ##.*( $’ *)&+# ,( ))’ % +((*& * &%% * &%*& 1. Make a sample crimp and determine if the ,( .( $’ *&(+) %**&&#*&( $’ contact is straight, bending upward, or bending ) (&%**)%- () /) 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. Assemble holds the contact support onto the locator applicable wire seal onto wire according to the assembly. instructions packaged with the contact. Strip the wire to the length indicated in Figure 1, taking care not to (**)*%*)**(*+ ## ")nick or cut wire strands. Select an applicable contact )**&&#%#)(#&) and identify the appropriate crimping chamber according to the wire size markings on the tool. Refer to Figure 3 and proceed as follows: 1. Hold the tool so that the back (wire side) is 3. Place a contact with wire into the proper nest facing you. Squeeze tool handles together and and close the tool handles until the ratchet reaches allow them to open fully. the sixth click, or until the contact support touches the contact. 2. Holding the contact by the mating end, insert the contact—insulation barrel first—through the front of 4. Slightly loosen the nut that holds the locator the tool and into the appropriate crimping chamber. assembly onto the tool frame. 3. Position the contact so that the mating end of 5. Move the contact support as required to the contact is on the locator side of the tool, and so eliminate the bending of the contact. that the open “U” of the wire and insulation barrels face the top of the tool. Place the contact up into 6. Tighten the nut and close the handles until the the nest so that the movable locator drops into the ratchet releases. slot in the contact. Refer to Figure 3. Butt the front 7. Remove and inspect the contact. end of the wire barrel against the movable locator. """ # " #!"" % """ ""&" # " " "" ! " "" Figure 3 $&" ! " !+#.’*-’+%,,)//$*")1 ")+(* *&* )!)&* !%)+#*!&%((#*-$.$*)*$). ()*(*,%#.!%*&* (!$’!% $(*) ). ,*! &**$’**&(!$’%!$’(&’(#.$, ,, ’ ’&)!*!&%&%**++*-$. ( 4. Hold the contact in position and squeeze the tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT 3*$!$ deform insulation barrel or wire barrel. )0$’ 5. Insert stripped wire (with wire seal) into contact insulation and wire barrels until it is butted against ’2$.’*-’+%&!*"$..’*-$’%&0the wire stop, as shown in Figure 3. ** ’.$’2$!.(’+%’*$+/’,+3! 6. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact. (!$’&%**$.)*!"!%* (!$’!% (+** &%**%)!#.($&,. ’+) !%&-%-(&%* *&’&* #&*&() !+(Figure 4 7. Check the contact crimp height as described in Section 6, CRIMP HEIGHT INSPECTION. If 3. Observe the ratchet adjustment wheel. If a necessary, adjust the crimp height as described in tighter crimp is required, rotate the adjustment Section 7, CRIMP HEIGHT ADJUSTMENT. wheel COUNTERCLOCKWISE to a higher–numbered setting. If a looser crimp is required, rotate the adjustment wheel CLOCKWISE to a lower–numbered setting. This inspection requires the use of a micrometer with 4. Replace the lockscrew. a modified anvil. 5. Make a sample crimp and measure the crimp height. If the dimension is acceptable, secure the.&#*(&%!)&)%&*$%+*+(&($("* lockscrew. If the dimension is unacceptable,* ))&-,((&$$%)* continue to adjust the ratchet, and again measure$&!!$!(&$*((!$’! *&$’(*&( a sample crimp.&(* !!*#!*+*&.& $!(&$*( Proceed as follows: , 1,$0 , 1. Refer to Figure 4 and select a wire (maximum size) for each crimping chamber listed. 2. Refer to Section 5, CRIMPING PROCEDURE, and crimp the contact(s) accordingly. 3. Using a crimp height comparator, measure the wire barrel crimp height as shown in Figure 4. If the crimp height conforms to that shown in the table, the tool is considered dimensionally correct. If not, the tool must be adjusted. Refer to Section 7, .# . CRIMP HEIGHT ADJUSTMENT. %/-.( ). # ’ .’*-$’%&0$"/, 1. Remove the lockscrew from the ratchet *&-, 1 adjustment wheel. 2+ 2. With a screwdriver, adjust the ratchet wheel Figure 5 from the locator side of the tool. *!2*’ .,*)$-*,+*,.$*) 0 ’.$ $’!#&!$ %%"((#") 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 The crimping dies should be inspected on a regular basis to ensure that they have not become worn or damaged. Inspect the crimping chambers for Since the previous release of this instruction sheet: flattened, chipped, worn, or broken areas. If damage The TE logo was applied; or abnormal wear is evident, the tool must be replaced. See Section 10, REPLACEMENT.The PRO–CRIMPER II hand tool became the PRO–CRIMPER III hand tool; and The format was updated to the current corporate requirements. Customer–replaceable parts are shown in Figure 1. 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.