Tyco Electronics PRO-CRIMPER III 58517 Series User manual

Instruction Sheet
PRO-CRIMPER* III Hand
Crimping Tool Assembly 408-4064
L C B
1 of 4
E 2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. ther products, logos, and company names used are the property of their respective owners.
T LING ASSISTANCE CENTER 1-800-722-1111
PR DUCT INF RMATI N1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
04 MAY 09 Rev C
58517- ]
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
The PR -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 114 application specification, 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.
Locator
(Supplied with
Die Assembly)
Front of Tool
(Locator Side)
Die Assembly
Moving Jaw
Ratchet Adjustment
Wheel
Moving Handle
Stationary
Handle
PR -CRIMPER III Hand
Crimping Tool Frame
354940-1 (Instruction
Sheet 408-9930)
Pivot Pin
Back of Tool
(Wire Side)
Stationary Jaw
PRO-CRIMPER III
Die Assembly
Locator
Contact
Wire
PRO
-
CRIMPER III
Hand Tool
Die Assembly
Part Number
Locator
Part Number {
Contact
Family }
Size
(AWG) Insul Dia
(mm {In.]) Strip Length (mm {In.])
58517-1 58517-2 189590-1 CST 100
26-22
0.89-1.65 2.54-2.92
58517-3 58517-4 1424907 CST 100 II
26
-
22
[.035-.065] [.100-.125]
{
Supplied with the die assembly. Also available separately. } Contact the PR DUCT INF RMATI N CENTER for specific contact part numbers. {
Figure 1
1. INTRODUCTION
PRO–CRIMPER III Hand Crimping Tool
Assembly 58517–1 consists of Die Assembly
58517–2 and PRO–CRIMPER III Hand Tool Frame
354940–1. See Figure 1.
PRO–CRIMPER III Hand Crimping Tool
Assembly 58517–3 consists of Die Assembly
58517–4 and PRO–CRIMPER III Hand Tool Frame
354940–1. See Figure 1.
The die assembly consists of crimping dies and a
locator assembly.
Read these instructions thoroughly before crimping
any contacts.
Dimensions on this sheet are in millimeters [with
inch equivalents provided in brackets]. Figures
and illustrations are for identification only and are
not drawn to scale.
Reasons for reissue are provided in Section 11,
REVISION SUMMARY.
NOTE
i

408-4064
PRO-CRIMPER III Hand Crimping Tool Assembly 58517-[
Rev C2 of 4 Tyco Electro ics Corporatio
Figure 2
Nut
Washer
Locator
Adjustme t
Screw Nut Tool Frame
Die Retai i g
Pi s
Die Retai i g
Screws
Chamfer
Wire Crimper
Offset
Wire A vil
I sulatio
Crimper
I sulatio
A vil
Chamfer
2. DESCRIPTION (Figures 1 a d 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 contact crimping.
The tool frame holds a die assembly with one
crimping section.
The die assembly features a wire anvil, an insulation
anvil, a wire crimper, and an insulation crimper.
Attached to the outside of the frame is a locator,
which holds and helps to position the contact.
Die retaining pins and die retaining screws are used
to position and secure the dies in the tool frame. A
washer and nut is used on the lower die retaining
screw to hold the locator in place.
3. INSTALLATION AND REMOVAL OF DIE SET
AND LOCATOR ASSEMBLY
(Figure 2)
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the wire anvil and insulation anvil in the
moving jaw so that their chamfered sides and their
marked surfaces face outward, when mounted in
the moving jaw of the tool frame.
3. Insert the two die retaining pins.
4. Insert the long die retaining screw through the
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.
5. Place the wire crimper and insulation crimper in
the stationary jaw so that their chamfered sides
and their marked surfaces face outward, when
mounted in the stationary jaw of the tool frame.
6. Insert the two die retaining pins.
7. Insert the short die retaining screw through the
jaw and through both crimper dies, and tighten the
screw just enough to hold the dies in place. Do
not
tighten the screw completely at this time.
8. Carefully close the tool handles, making sure
that the anvils and crimpers align properly.
Continue closing the tool handles until the ratchet
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 over the end of the long screw,
and position the locator against the side of the tool
jaw.
10. Place the washer and nut onto the end of the
long screw. Align the locator slot with the crimping
section and carefully tighten the nut.
11. To disassemble, close the tool handles until the
ratchet releases, remove the nut, the washer, the
locator, the two die retaining screws, and the four
die retaining pins, and slide the anvils and crimpers
out of the tool jaws.

408-4064
PRO-CRIMPER III H nd Crimping Tool Assembly 58517-[ ]
3 of 4Rev C
Ty o Ele troni s Corporation
4. CRIMPING PROCEDURE
Th s tool s prov ded w th a cr mp adjustment
feature. Int ally, the cr mp he ght should be
ver f ed as spec f ed n F gure 4. Refer to
Sect on 6, CRIMP HEIGHT INSPECTION, and
Sect on 7, CRIMP HEIGHT ADJUSTMENT, to
ver fy cr mp he ght before us ng the tool to cr mp
des red contacts and w re s zes.
Refer to the table in Figure 1 and select wire of the
specified size and insulation diameter. 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 die assembly according to
the wire size markings on the die. Refer to Figure 3
and proceed as follows:
1. Hold the tool so that the back (wire side) is
facing you. Squeeze tool handles together and
allow them to open fully.
2. Holding the contact by the insulation barrel,
insert the contact — mating end first — into the
locator slot. Position the contact so that the open
“U” of the wire and insulation barrels face the top of
the tool. Make sure the contact butts against the
adjustment screw. Check that the contact is
centered with the die assembly wire and insulation
anvils. If adjustment is required, refer to Section 5,
CONTACT SUPPORT ADJUSTMENT.
Make sure that both s des of the nsulat on barrel
are started evenly nto the cr mpng sect on. Do
NOT attempt to cr mp an mproperly pos t oned
contact.
3. Hold the contact in position and squeeze the
tool handles together until ratchet engages
sufficiently to hold the contact in position. Do NOT
deform insulation barrel or wire barrel.
The ratchet has detents that create aud ble cl cks
as the tool handles are closed.
4. Insert stripped wire into contact insulation and
wire barrels until it is butted against the wire stop
on the contact, as shown in Figure 3.
5. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped contact.
6. Check the contact’s crimp height as described in
Section 6, CRIMP HEIGHT INSPECTION. If
necessary, adjust the crimp height as described in
Section 7, CRIMP HEIGHT ADJUSTMENT.
5. CONTACT SUPPORT ADJUSTMENT (Figure 3)
1. Make a sample crimp according to Section 4,
CRIMPING PROCEDURE. If the crimp is out of
alignment, adjustment is required.
2. To move the contact from side–to–side, loosen
the nut that holds the locator to the frame and slide
the locator until the contact is properly positioned.
Hold the locator in place and tighten the nut.
3. To move the contact in or out, loosen the nut on
the adjustment screw and turn the screw until the
contact is properly positioned. Hold the screw in
place and tighten the nut.
Figure 3
Ba k of Tool
(Wire Side)
Lo ator Slot Wire
Adjustment
S rew
Lo ator
Wire Inserted
to Conta t
Wire Stop
Wire Inserted
in Conta t
Strip
Length
A"
Tool No. Dim ``A"
58517-1 & 58517-2 2.641 [.104]
58517-3 & 58517-4 4.191 [.165]
NOTE
i
CAUTION
!
NOTE
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408-4064
PRO-CRIMPER III Hand Crimping Tool Assembly 58517-[ ]
Rev C4 of 4 Tyco Electronics Corpor tion
Wire Size
AWG (Max) Crimp Section
(Wire Size Marking)
Crimp Height
Dim. (A) and
Tolerance (+)
A"
22 26-22 0.79 +0.05
[.031 " .002]
Figure 4
Position Point
on Center of
Wire B rrel
Opposite Se m
Modified
Anvil
4. If the crimp is still out of alignment, repeat the
adjustment procedure.
6. CRIMP HEIGHT INSPECTION
This inspection requires the use of a micrometer with
a modified anvil.
Tyco Electronics does not manufacture or market
these gages. However, TE recommends the
modified micrometer (Crim Height Com arator
RS-1019-5LP) .
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for the crimp section.
2. Refer to Section 4, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
Figure 5
Screwdriver
R tchet
Adjustment
Wheel
Lockscrew
(Typ)
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.
7. CRIMP HEIGHT ADJUSTMENT (Figure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the locator side of the tool.
3. Observe the ratchet adjustment wheel. If a
tighter crimp is required, rotate the adjustment
wheel COUNTERCLOCKWISE to a
higher–numbered setting. If a looser crimp is
required, rotate the adjustment wheel
CLOCKWISE to a lower–numbered setting.
4. Replace the lockscrew.
5. Make a sample crimp and measure the crimp
height. If the dimension is acceptable, replace and
secure the lockscrew. If the dimension is
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp.
8. 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.
9. ISUAL INSPECTION
The crimping dies should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimp section for flattened,
chipped, worn, or broken areas. If damage or
abnormal wear is evident, the tool must be replaced.
See Section 10, REPLACEMENT.
10. REPLACEMENT
Customer–replaceable parts are shown in Figure 1.
Available separately, PRO–CRIMPER III Hand 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. 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 1–717–986–7605, or write to:
11.RE ISION SUMMARY
Since the previous release of this sheet, the following
changes were made:
S TE logo was applied; and
S PRO–CRIMPER II Hand Tool was changed to
PRO–CRIMPER III Hand Tool.
NOTE
i