Tyco Electronics PRO-CRIMPER II User manual

Instruction Sheet
PRO–CRIMPER* II
Hand Tool Assembly 58546–1 408–4047
E 2003 Tyco Electronics Corporation, Harrisburg, PA
AllInternationalRightsReserved
AMP and Tyco are trademarks. *Trademark
Other products, logos, and company names used are the property of their respective owners. LOC B
1 of 5
TOOLINGASSISTANCE CENTER 1–800–722–1111
FAX/PRODUCTINFO1–800–522–6752
For Regional Customer Service, visit our website at
www.tycoelectronics.com
This controlled document is subject to change.
For latest revision, call the FAX/PRODUCT INFO number.
24 OCT 03 Rev D
with Die Assembly 58545–1
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended–use, production operations is available.
The PRO–CRIMPER II Hand 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 114 application specification, but may not comply with other
feature parameters of the specification. Tyco Electronics offers avariety of
tools to satisfy your performance requirements. For additional information,
contact the Tooling Assistance Center at 1–800–722–1111.
Front of Tool
DieAssembly
MovingJaw
RatchetAdjustment
Wheel
Moving
Handle
Stationary
Handle
PRO–CRIMPER II Hand Tool
Frame354940–1
(SeeInstruction
Sheet408–9930)
Pivot Pin
Back of Tool
(WireSide)
StationaryJaw
Y
WIRE
DIE ASSEMBL
Y
PRODUCT
FAMILY }
SIZE
(AWG) STRIP LENGTH
(mm [in.])
58545–1 SOLISTRAND* Butt Splice 22–10 6.35–7.14 [.25–.281]
} Contact the Tooling Assistance Center at the number listed below for specific splice part numbers.
Figure 1
1. INTRODUCTION
PRO–CRIMPER II Hand Tool Assembly 58546–1
consists of Die Assembly 58545–1 and
PRO–CRIMPER II Hand Tool Frame 354940–1. The
tool is used to crimp the splices onto the wire size
listed in Figure 1.
Read these instructions thoroughly before crimping
any splices.
Dimensions on this sheet are in millimeters [with
inchequivalents provided in brackets].
Reasons for reissue of this instruction sheet are
provided in Section 10, REVISION SUMMARY.
2. DESCRIPTION (Figures 1 and 2)
The tool features a tool frame with a stationary jaw
and handle, a moving jaw, a moving handle, and an
adjustable ratchet that ensures full crimping.
The tool frame holds a die assembly with three
crimping chambers. The die assembly features an
upper die and a lower die. Die retaining screws are
used to position and secure the dies in the tool frame.
NOTE

408–4047
PRO–CRIMPER II Hand Tool Assembly 58546–1
Rev D2 of 5
Figure 2
UpperDie
LowerDie
Indenters Anvils
DieRetaining
Screws
StationaryJaw
3. DIE ASSEMBLY INSTALLATION AND REMOVAL
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the upper die in the stationary jaw of the
tool frame so that the largest indenter is facing
inward. See Figure 2.
3. Insert the die retaining screw through the
stationary jaw and through the die. Tighten the
screw just enough to hold the die in place. Do
not
tighten the screw completely at this time.
4. Place the lower die in the moving jaw of the tool
frame so that the largest anvil is facing inward. See
Figure 2.
5. Insert the die retaining screw through the
moving jaw and through the die. Tighten the screw
just enough to hold the die in place. Do not tighten
the screw completely at this time.
6. Carefully close the tool handles, making sure
that the anvils and indenters align properly.
Continue closing the tool handles until the ratchet
has engaged sufficiently to hold the dies in place,
then tighten both die retaining screws.
7. To disassemble, open the tool handles until the
ratchet releases, remove the two die retaining
screws, and slide the dies out of the tool jaws.
4. CRIMPING PROCEDURE
Before using the tool, the crimping chambers and
tool ratchet should be inspected as specified in
Section 5, CRIMP HEIGHT INSPECTION, and
Section6,SHUTHEIGHTADJUSTMENT.
Refer to Figure 1 and select wire of the specified size
and insulation diameter. Strip the wire to the length
indicated, taking care not to nick or cut wire strands.
Select an applicable splice and identify the
appropriate crimping chamber according to the wire
size markings on the dies. Refer to Figure 3 and
proceed as follows:
1. Hold tool so that the back (wire side) is facing
you. Squeeze tool handles together until the
ratchet releases, then allow them to open fully.
2. Center the splice wire barrel on the anvil of the
upper die as shown in Figure 3. If visible, be sure
to place the brazed seam on the splice toward the
indenter.
3. Hold the wire barrel in place and squeeze the
tool handles together until ratchet engages
sufficiently to hold the splice in position. Do NOT
deform the insulation barrel or wire barrel.
4. Insert stripped wire into the wire barrel, making
sure that the insulation does not enter the wire
barrel. See Figure 3.
5. Holding wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open, then remove crimped splice.
NOTE

408–4047
PRO–CRIMPER II Hand Tool Assembly 58546–1
3of 5Rev D
Figure 3
Splice Wire Barrel
Centered on Anvil of
LowerDie
BrazedSeam
PositionedToward
Indenter
6. To crimp the other half of a splice, reposition the
uncrimped wire barrel in the crimping chamber, and
repeat the crimping procedure.
If splice cannot be turned for crimping the other
half, turn the tool around.
7. Inspect the crimped splice according to
Figure 4. Check the crimp height as described in
Section 5. If necessary, adjust the shut height as
described in Section 6.
Damaged splices may not be used. If a damaged
splice is evident, it must be replaced with a new
one.
Figure 4
1
3
2
4
InspectionHole
3
2
4
1
3
Crimp is centered on wire barrel. It is acceptable for
crimp to be slightly off center, but NOT OFF THE END of
the wire barrel.
Wire size being used matches wire size range stamped
on splice and dies.
Wire insulation does not enter wire barrel.
Wire is flush with or extends slightly beyond end of wire
barrel. Wire is visible through inspection hole of splices.
NOTE CAUTION

408–4047
PRO–CRIMPER II Hand Tool Assembly 58546–1
Rev D4 of 5
5. CRIMP HEIGHT INSPECTION
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 5.
Tyco Electronics does not manufacture or market
these gages. To gage the crimping chamber, proceed
as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Close the tool handles until the dies have
bottomed. Do NOT force dies beyond initial
contact.
3. Align the GO element with the crimping
chamber. Push element straight into the crimping
chamber without using force.
Suggested Plug Gage Design
DieClosure
Configuration
“R”
12.7[.50]
Min Typ
GO
Dim.
50.8[2.00]
Min Typ
“R”
NO–GO
Dim.
CRIMPING GAGE ELEMENT DIMENSIONS
CHAMBER
(Die Marking) GO NO–GO “R”
(Radius)
22–18 1.143–1.151
[.0450–.0453] 1.344–1.346 [.0529–.0530] 1.57 [.062]
16–14 1.346–1.354
[.0530–.0533] 1.547–1.549 [.0609–.0610] 1.98 [.078]
12–10 1.905–1.913
[.0750–.0753] 2.106–2.108 [.0829–.0830] 2.77 [.109]
Figure 5
NO–GO Element May Start Entry, But Must Not
PassCompletely Through Crimping Chamber
GO Element Must Pass Completely
ThroughCrimping Chamber
The GO element must pass completely through the
crimping chamber. See Figure 5.
4. Align the NO–GO element and try to insert it
straight into the same crimping chamber. The
NO–GO element may start entry, but must not
pass completely through the crimping chamber.
See Figure 5.
If the crimping chamber conforms to the gage
inspection, the tool is considered dimensionally
correct, and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If not, the tool must be
returned to Tyco Electronics for further evaluation and
repair. Refer to Section 8, REPLACEMENT.
For additional information regarding the use of a plug
gage, refer to instruction sheet 408–7424.
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
Figure 6
6. 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 the opposite side of the frame.
3. Observe the ratchet adjustment wheel. If the
dies do not bottom, rotate the adjustment wheel
COUNTERCLOCKWISE to a higher–numbered
setting.
4. Replace the lockscrew.

408–4047
PRO–CRIMPER II Hand Tool Assembly 58546–1
5of 5Rev D
7. MAINTENANCE AND INSPECTION
7.1. Maintenance
Ensure that the tool and dies are clean by wiping
them with a clean, soft cloth. Remove any debris with
a clean, soft brush. Do not use objects that could
damage the tool. When not in use, keep handles
closed to prevent objects from becoming lodged in
the crimping dies, and store in a clean, dry area.
7.2. Visual Inspection
The die assembly should be inspected on a regular
basis to ensure that they have not become worn or
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
replaced. See Section 8, REPLACEMENT.
8. REPLACEMENT
Customer–replaceable parts are shown in Figure 1.
Available separately, PRO–CRIMPER II 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.
Order the repair kit and replaceable parts through
your Tyco Electronics Representative, or call
1–800–526–5142, or send a facsimile of your
purchase order to 717–986–7605, or write to:
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG, PA 17105–3608
For tool repair service, please contact a Tyco
Electronics Representative at 1–800–526–5136.
9. STANDARD SOLISTRAND TERMINALS
To crimp standard SOLISTRAND terminals and
parallel splices, refer to Instruction Sheet 408–8678.
10. REVISION SUMMARY
Revisions to this instruction sheet per
EC 0990–1181–03 include:
S Updated document to corporate requirements
S Added markings to dies in Figure 2
S Changed wire size range from 22–16 to 22–18
in table in Figure 5