Instruction Sheet PRO-CRIMPER*IIIHandCrimping ToolAssembly58641-1with 408--4379 DieAssembly58641-2 18 JUN 09 RevA PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awide selection ofpowered application equipmentforextended--use,production operationsisavailable. 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 Frame Die Assembly 354940--1 ( 408--9930) Moving Jaw Ratchet Adjustment Wheel The PRO--CRIMPER IIIHand Crimping Tool isa “Commercial”grade tool and Stationary Handle isdesigned primarilyforfield installation,repair,maintenance work,or prototyping in industrial,commercial,orinstitutional applications.Product crimped with thistool will meetthe crimp heightrequirementforhand toolsin the appropriate 114 seriesspecification,butmaynotcomplywith otherfeature parametersofthe specification.Tyco Electronicsoffersa varietyoftoolsto Moving Handle satisfyyourperformance requirements.Foradditional information,contactthe Tooling Assistance Centerat1--800--722--1111. Wire TEDieAssembly LocatorAssembly{ ContactFamily} Size InsulDia StripLength (AWG) (mm[in.]) (mm[in.]) 26 -- 24 1.02 1.02 ---- 1.52 1.52 4.37 4.37 ---- 3.58 3.58 5 58641 8641--2 2 5 58516 8516--1 1 A AM MP PMO MOD DU U** IIV V [.040 -- .060] [.172 -- .141] 22 { Supplied with die assembly,also available separately. } Contactthe Tooling Assistance Centerorthe Product Information Center(see below)forspecificcontactpartnumbers. Figure 1 1. INTRODUCTION Dimensions on this sheet are in millimeters [with NOTE inch equivalents provided in brackets]. Figures and illustrations are for identification only and are i PRO--CRIMPER III Hand Crimping Tool Assembly not drawn to scale. 58641--1 consists of Die Assembly 58641--2 and PRO--CRIMPER III Hand Crimping Tool Frame 354940--1. The die assembly consists of crimping 2. DESCRIPTION (Figures1 and 2) dies and a locator assembly. The tool features a tool frame with a stationary jaw and handle, a moving jaw, a moving handle, and an Read these instructions thoroughly before crimping adjustable ratchet that ensures full contact crimping. any contacts. The tool frame holds a die assembly with two crimping sections. Reasons for revision can be found in Section 11, The die assembly features a wire anvil, an insulation REVISION SUMMARY. anvil, a wire crimper, and an insulation crimper. E2009 Tyco Electronics Corporation, Harrisburg, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlled document is subject to change. 1 of 5 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. 408-4379 PRO-CRIMPERIIIHandCrimpingToolAssembly58641-1 Nut Locator Tool Frame Assembly Insulation Die Retaining Pins Crimper Chamfer Wire Crimper Offset Wire Anvil Chamfer Insulation Anvil Die Retaining Screws Figure 2 Attached to the outside of the frame is a locator screw just enough to hold the dies in place. Do not assembly, which contains a locator, a spring retainer, tighten the screw completely at this time. and a contact support. 8. Carefully close the tool handles, making sure Die retaining pins and die retaining screws are used that the anvils and crimpers align properly. to position and secure the dies in the tool frame. A Continue closing the tool handles until the ratchet nut is used on the upper die retaining screw to hold in the tool frame has engaged sufficiently to hold the locator assembly in place. the anvils and crimpers in place, then tighten both die retaining screws. 9. Place the locator assembly over the end of the 3. INSTALLATIONANDREMOVALOFDIESET long screw, and position the locator assembly ANDLOCATORASSEMBLY (Figure 2) against the side of the tool jaw. 1. Open the tool handles and remove the two die retaining screws from the tool jaws. 10. Place the nut onto the end of the long screw and tighten the nut enough to hold the locator 2. Place the wire anvil and insulation anvil so that assembly in place, while still allowing the locator to their chamfered sides and their marked surfaces slide up and down. face outward, when mounted in the moving jaw of the tool frame. 11. To disassemble, close the tool handles until the ratchet releases, remove the nut, the locator 3. Insert the two die retaining pins. assembly, the two die retaining screws, and the four die retaining pins, and slide the anvils and 4. Insert the short die retaining screw through the crimpers out of the tool jaws. jaw and through both anvil dies, and tighten the screw just enough to hold the dies in place. Do not tighten the screw completely at this time. 4. CONTACTSUPPORTADJUSTMENT (Figure 3) 5. Place the wire crimper and insulation crimper so The contact support is preset prior to shipment, NOTE that their chamfered sides and their marked but minor adjustment may be necessary. surfaces face outward, when mounted in the stationary jaw of the tool frame. i 6. Insert the two die retaining pins. 1. Make a sample crimp and determine if the 7. Insert the long die retaining screw through the contact is straight, bending upward, or bending jaw and through both crimper dies, and tighten the downward. 2 of 5 Tyco ElectronicsCorporation RevA 408-4379 PRO-CRIMPERIIIHandCrimpingToolAssembly58641-1 2. If adjustment is required, loosen the screw that Refer to the table in Figure 1 and select wire of the holds the contact support onto the locator specified size and insulation diameter. Strip the wire assembly. to the length indicated in Figure 1, taking care not to nick or cut wire strands. Select an applicable contact The ratchet has detents that create audible clicks NOTE and identify the appropriate crimp section according as the tool handles are closed. to the wire size markings on the tool. Refer to Figure 3 and proceed as follows: i 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 4. Slightly loosen the nut that holds the locator of the tool and into the appropriate crimp section. assembly onto the tool frame. 5. Move the contact support as required to 3. Position the contact so that the mating end of eliminate the bending of the contact. the contact is on the locator side of the tool, and so that the open “U” of the wire and insulation barrels 6. Tighten the nut and close the handles until the must face the top of the tool. Place the contact up ratchet releases. into the nest so that the movable locator drops into 7. Remove and inspect the contact. the slot in the contact. Refer to Figure 3. Butt the front end of the wire barrel against the movable 8. Make another sample crimp. If the contact is locator. straight, tighten the contact support screw. If the contact is still being bent during crimping, repeat Make sure that both sides of the insulation barrel the adjustment procedure. CAUTION are started evenly into the crimping section. Do NOT attempt to crimp an improperly positioned ! 5. CRIMPINGPROCEDURE contact. This tool is provided with a crimp adjustment NOTE feature. Initially, the crimp height should be verified as specified in Figure 4. Refer to Section 4. Hold the contact in position and squeeze the i 6, CRIMP HEIGHT INSPECTION, and Section 7, tool handles together until ratchet engages RATCHET ADJUSTMENT, to verify crimp height sufficiently to hold the contact in position. Do NOT before using the tool to crimp desired contacts deform insulation barrel or wire barrel. and wire sizes. Contact Locator Support Back of Tool (Wire Side) Adjustment Contact Screw for Strip Length (Typ) Contact Support Wire Locator in Wire Stop Slot Wire Inserted to Stop Figure 3 RevA Tyco ElectronicsCorporation 3 of 5 408-4379 PRO-CRIMPERIIIHandCrimpingToolAssembly58641-1 5. Hold the contact in position and squeeze the Position Point tool handles together until ratchet engages on Center of sufficiently to hold the contact in position. Do NOT Wire Barrel deform insulation barrel or wire barrel. Opposite Seam 6. Insert stripped wire into contact insulation and wire barrels until it is butted against the wire stop, as shown in Figure 3. Modified Anvil “A” 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles CRIMPHEIGHT WIR WIRE ES SIZE IZE CRI CRIM MP PS SE EC CT TIIO ON N to open and remove crimped contact. D DIIM M.((A A))A AND ND AWG(MAX) (WIRESIZEMARKING) TOLERANCE(+) The crimped contact may stick in the crimping NOTE .76 + .05 area, but the contact can be easily removed by 24 26 -- 24 [.030 + .002] pushing downward on the top of the locator (see i Figure 3). .86 + .05 22 22 [.034 + .002] 8. Check the contact’s crimp height as described in Figure 4 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, RATCHET (Crimp Height) wheel COUNTERCLOCKWISE to a ADJUSTMENT. higher--numbered setting. If a looser crimp is 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 of a micrometer with a modified anvil, commonly 5. Make a sample crimp and measure the crimp referred to as a crimp--height comparator. Tyco height. If the dimension is acceptable, replace and Electronics does not manufacture or market secure the lockscrew. If the dimension is crimp--height comparators. Detailed information on unacceptable, continue to adjust the ratchet, and obtaining and using crimp--height comparators can be again measure a sample crimp. found in instruction sheet 408--7424. Proceed as follows: Screwdriver 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 crimp height conforms to that shown in the table, Ratchet the tool is considered dimensionally correct. If not, Adjustment the tool must be adjusted. Refer to Section 7, Wheel CRIMP HEIGHT ADJUSTMENT. 7. RATCHET(Crimp Height) ADJUSTMENT (Figure 5) Lockscrew 1. Remove the lockscrew from the ratchet (Typ) adjustment wheel. 2. With a screwdriver, adjust the ratchet wheel Figure 5 from the locator side of the tool. 4 of 5 Tyco ElectronicsCorporation RevA 408-4379 PRO-CRIMPERIIIHandCrimpingToolAssembly58641-1 8. MAINTENANCE Order the repair kit and replaceable parts through Ensure that the tool and dies are clean by wiping your Tyco Electronics representative, or call them with a clean, soft cloth. Remove any debris with 1--800--526--5142, or send a facsimile of your a clean, soft brush. Do not use objects that could purchase order to 1--717--986--7605, or write to: damage the tool. When not in use, keep handles closed to prevent objects from becoming lodged in CUSTOMER SERVICE (38--35) the crimping dies, and store in a clean, dry area. TYCO ELECTRONICS PO BOX 3608 HARRISBURG PA 17105--3608 9. VISUALINSPECTION The crimping dies should be inspected on a regular 11.REVISIONSUMMARY basis to ensure that they have not become worn or Revisions to this instruction sheet include: damaged. Inspect the crimp sections for flattened, chipped, worn, or broken areas. If damage or S PRO--CRIMPER II Hand Tool became the abnormal wear is evident, the tool must be replaced. PRO--CRIMPER III Hand Tool; See Section 10, REPLACEMENT. S TE logo was applied; S Changed crimp height comparator information. 10. REPLACEMENT 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. RevA Tyco ElectronicsCorporation 5 of 5