Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 58614-1 with 408-4228 Die Assembly 58614-2 05 MAY 11 Rev C 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. Locator Assembly Stationary Jaw (Supplied with Die Assembly) Back of Tool (Wire Side) Front of Tool (Locator Side) Pivot Pin PRO-CRIMPER III Hand Crimping Tool Die Assembly Frame 354940-1 Moving Jaw (408-9930) Ratchet Adjustment Wheel Stationary Handle The PRO-CRIMPER III Hand Crimping Tool is a “Commercial" grade Moving Handle 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. Tyco Electronics offers a variety of tools to satisfy your performance requirements. For additional information, contact the Tooling Assistance Center at 1-800-722-1111. WIRE TE DIE LOCATOR CONTACT SIZE INSULATION STRIP LENGTH ASSEMBLY ASSEMBLY † FAMILY ‡ (AWG) DIAMETER (mm [In.] 24 - 20 L 1.52 - 2.79 SL156 18 [.060 - .110] 3.96 ± 0.38 58614-2 58515-1 Series [.156 ± .015] 1.09 - 1.91 Connectors 24 - 20 S [.043 - .075 † Supplied with die assembly. Also available separately. ‡Contact the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION (see below) for specific contact part numbers. Figure 1 Dimensions on this sheet are in millimeters [with 1. INTRODUCTION NOTE inch equivalents provided in brackets]. Figures and PRO-CRIMPER III Hand Crimping Tool Assembly illustrations are for identification only and are not i 58614-1 consists of Die Assembly 58614-2 and PRO- drawn to scale. CRIMPER III Hand Crimping Tool Frame 354940-1. The die assembly consists of crimping dies and a Reasons for revision are listed in Section 11, locator assembly. REVISION SUMMARY. Read these instructions thoroughly before crimping any contacts. © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company 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. 408-4228 2. DESCRIPTION (Figure 1 and 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. The tool frame holds a die assembly with three 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 assembly, which contains a locator, a spring retainer, 7. Insert the long die retaining screw through the and a contact support. jaw and through both crimper dies, and tighten the screw just enough to hold the dies in place. Do not Die retaining pins and die retaining screws are used to tighten the screw completely at this time. position and secure the dies in the tool frame. A nut is used on the upper die retaining screw to hold the 8. Carefully close the tool handles, making sure that locator assembly in place. the anvils and crimpers align properly. Continue closing the tool handles until the ratchet in the tool 3. INSTALLATION AND REMOVAL OF DIE SET AND frame has engaged sufficiently to hold the anvils LOCATOR ASSEMBLY (Figure 2) and crimpers in place, then tighten both die retaining screws. 1. Open the tool handles and remove the two die retaining screws from the tool jaws. 9. Place the locator assembly over the end of the long screw, and position the locator assembly 2. Place the wire anvil and insulation anvil so that against the side of the tool jaw. their chamfered sides and their marked surfaces face outward, when mounted in the moving jaw of 10. Place the nut onto the end of the long screw and the tool frame. tighten the nut enough to hold the locator assembly in place, while still allowing the locator to slide up 3. Insert the two die retaining pins. and down. Locator Nut Assembly Tool Frame Insulation I Crimper Die Retaining Pins Chamfer Wire  Crimper Offset Chamfer Wire Anvil Die Retaining Screws Insulation Anvil Figure 2 Rev C 2 of 6 408-4228 11. To disassemble, close the tool handles until the 6. Tighten the nut and close the handles until the ratchet releases, remove the nut, the locator ratchet releases. assembly, the two die retaining screws, and the four 7. Remove and inspect the contact. die retaining pins, and slide the anvils and crimpers out of the tool jaws. 8. Make another sample crimp. If the contact is straight, tighten the contact support screw. If the 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) contact is still being bent during crimping, repeat the adjustment procedure. The contact support is preset prior to shipment, but NOTE minor adjustment may be necessary. 5. CRIMPING PROCEDURE i This tool is provided with a crimp adjustment feature. Initially, the crimp height should be verified as 1. Make a sample crimp and determine if the specified in Figure 4. Refer to Section 6, Crimp Height contact is straight, bending upward, or bending Inspection, and Section 7, RATCHET Adjustment, to downward. verify crimp height before using the tool to crimp desired contacts and wire sizes. 2. If adjustment is required, loosen the screw that holds the contact support onto the locator assembly. Refer to the table in Figure 1 and select wire of the specified size and insulation diameter. Strip the wire to The ratchet has detents that create audible clicks NOTE the length indicated in Figure 1, taking care not to nick as the tool handles are closed. or cut wire strands. Select an applicable contact and i identify the appropriate crimp section according to the wire size markings on the tool. Refer to Figure 3 and proceed as follows: 3. Place a contact with wire into the proper nest and close the tool handles until the ratchet reaches the 1. Hold the tool so that the back (wire side) is facing sixt# click, or until the contact support touches the you. Squeeze tool handles together and allow them contact. 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 of the tool and into the appropriate crimp section. 5. Move the contact support as required to eliminate the bending of the contact. Contact Support Locator Back of Tool (Wire Side) Adjustment Contact Strip Length Screw for (Typ) Contact Support Locator in Wire Wire Stop Slot Wire Inserted to Stop Figure 3 Rev C 3 of 6 408-4228 3. Position the contact so that the mating end of the contact is on the locator side of the tool, and so that the open "U" of the wire and insulation barrels must face the top of the tool. Place the contact up into the nest so that the movable locator drops into the slot in the contact. Refer to Figure 3. Butt the front end of the wire barrel against the movable locator. Make sure that both sides of the insulation barrel CAUTION are started evenly into the crimping section. Do not attempt to crimp an improperly positioned contact. CRIMP HEIGHT ! CRIMP SECTION WIRE SIZE DIM.(A) AND (WIRE SIZE AWG (Max) TOLERANCE MARKINGS) 4. Hold the contact in position and squeeze the tool (±) .05 [.002] handles together until ratchet engages sufficiently to 20 24-20 L 1.02 [.040] hold the contact in position. Do NOT deform insulation barrel or wire barrel. 18 18 1.30 [.051] 20 24-20 S 1.02 [.040] 5. Insert stripped wire into contact insulation and wire barrels until it is butted against the wire stop, as Figure 4 shown in Figure 3. 2. With a screwdriver, adjust the ratchet wheel from 6. Holding the wire in place, squeeze tool handles the locator side of the tool. together until ratchet releases. Allow tool handles to open and remove crimped contact. 3. Observe the ratchet adjustment wheel. If a tighter crimp is required, rotate the adjustment wheel The crimped contact may stick in the crimping area, NOTE COUNTERCLOCKWISE to a higher-numbered but the contact can be easily removed by pushing setting. If a looser crimp is required, rotate the downward on the top of the locator (see Figure 3). i adjustment wheel CLOCKWISE to a lower- numbered setting. 7. Check the contact's crimp height as described in 4. Replace the lockscrew. Section 6, Crimp Height Inspection. If necessary, adjust the crimp height as described in Section 7, 5. Make a sample crimp and measure the crimp RATCHET ADJUSTMENT. height. If the dimension is acceptable, replace and secure the lockscrew. If the dimension is 6. CRIMP HEIGHT INSPECTION unacceptable, continue to adjust the ratchet, and again measure a sample crimp. Crimp height inspection is performed through the use of a micrometer with a modified anvil, commonly referred to as a crimp-height comparator. Tyco Electronics does not manufacture or market crimp- Screwdriver height comparators. Detailed information on obtaining and using crimp-height comparators can be found in Instruction Sheet 408-7424. Proceed as follows: 1. Refer to Figure 1 and select a wire (maximum size) for each crimp section listed. 2. Refer to Section 5, CRIMPING PROCEDURE, and crimp the contact(s) accordingly. Ratchet 3. Using a crimp height comparator, measure the Adjustment wire barrel crimp height as shown in Figure 4. If the Wheel 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 ADJUSTMENT. Lockscrew (Typ) 7. RATCHET ADJUSTMENT (Figure 5) 1. Remove the lockscrew from the ratchet adjustment wheel. Figure 5 Rev C 4 of 6 408-4228 8. MAINTENANCE Available separately, PRO-CRIMPER III Hand Crimping Tool Repair Kit 679221-1 includes a Ensure that the tool and dies are clean by wiping them replacement nut and a variety of pins, rings, screws, with a clean, soft cloth. Remove any debris with a and springs. 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 the must be replaced. 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 9. VISUAL INSPECTION facsimile of your purchase order to 1-717-986-7605, or The crimping dies should be inspected on a regular write to: basis to ensure that they have not become worn or damaged. Inspect the crimp sections for flattened, CUSTOMER SERVICE (038-035) chipped, worn, or broken areas. If damage or TYCO ELECTRONICS CORPORATION abnormal wear is evident, the tool must be replaced. PO BOX 3608 See Section 10, REPLACEMENT. HARRISBURG PA 17105-3608 11. REVISION SUMMARYSINCE 10. REPLACEMENT Since this sheet was revised, the new company logo Customer-replaceable parts are shown in Figure 1. has been applied. Rev C 5 of 6 408-4228 Toling Compatible with Die Assembly 58614-2 PRO-CRIMPER III Hand Tool Frame 354940-1 SDE-SA Hand Tool 9-1478240-0 (Instruction Sheet 408-9930) (Instruction Sheet 408-8851) SDE Bench Terminator 1490076-2 626 Adapter 679304-1 (Customer Manual 409-10052) (Instruction Sheet 408-4070) Electro-Hydraulic (BT 3500 Battery-Hydraulic) Closed Head Assembly 2031460-1 “C”-Head Assembly 2031450-1 Hand Tool Kits 2031400-[ ] (Instruction Sheet 408-10312) (Instruction Sheet 408-10311) (Customer Manual 409-10095) Rev C 6 of 6