Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO-CRIMPER* III Hand Crimping
ool Assembly 58508-1 with 408-4372
L C B
1 of 5
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 N 1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
16 JUN 09 Rev B
Die Assembly 58509-1
PROPER USE GUIDELINES
CumulativeTrauma Disorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
The PR -CRIMPER III Hand Crimping Tool Assembly 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 series 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.
Moving Handle
Stationary Handle
Stationary Jaw
Back of Tool
(Wire Side)
Pivot Pin
PR -CRIMPER III Hand
Crimping Tool Frame
354940-1 ( 408-9930)
Ratchet Adjustment Wheel
Moving Jaw
Die Assembly
Front of Tool
Wire
E Die Assembly Product Family
}
Size
(AWG)
Strip Length (mm [in.])
(AWG) erminal Butt Splice
58509 1
Bud
g
et Terminal and 22-14 4.37-5.16
[.172-.203] 6.35-7.14
58509
-
1
g
Butt Splice 12-10 6.35-7.14
[.250-.281]
[.250-.281]
} Contact the Tooling Assistance Center or the Product Information Center at the numbers listed below for specific terminal and butt splice
part numbers.
Figure 1
1. IN RODUC ION
PRO–CRIMPER III Hand Crimping Tool Assembly
58508–1 consists of Die Assembly 58509–1 and
PRO–CRIMPER III Hand Crimping Tool Frame
354940–1. The tool is used to crimp the terminals and
butt splices onto wire sizes listed in Figure 1.
Read these instructions thoroughly before crimping
any terminals or butt splices.
Reasons for reissue are provided in Section 10,
REVISION SUMMARY.
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.
2. DESCRIP ION (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 contact crimping.
The tool frame holds a die assembly with three
crimping sections.
NO E
i

408-4372
PRO-CRIMPER III Hand Crimping Tool Assem ly 58508-1
Rev B2 of 5 Tyco Elect onics Co po ation
Figure 2
Tool F ame
Die Retaining
Sc ews
Wi e C impe
Wi e Anvil
22-16" Ma king on
C imping Section
The die assembly features a wire anvil and a wire
crimper. Die retaining screws are used to secure the
dies in the tool frame.
3. INSTALLATION AND REMOVAL OF DIE SET (Figu e 2)
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the wire anvil so that the crimping section
marked “22–16” faces outward when mounted in
the stationary jaw of the tool frame.
3. Insert the die retaining screw through the jaw
and through the anvil, and tighten the screw just
enough to hold the anvil in place. Do
not tighten
the screw completely at this time.
4. Place the wire crimper so that the crimping
section marked “22–16” faces outward when
mounted in the moving jaw of the tool frame.
5. Insert the die retaining screw through the jaw
and through the crimper, and tighten the screw just
enough to hold the crimper in place. Do not tighten
the screw completely at this time.
6. Carefully close the tool handles, making sure
that the anvil and crimper align properly. Continue
closing the tool handles until the ratchet in the tool
frame has engaged sufficiently to hold the anvil
and crimper in place, then tighten both die retaining
screws.
7. To disassemble, close the tool handles until the
ratchet releases, remove the two die retaining
screws and slide the anvil and crimper out of the
tool jaws.
4. CRIMPING PROCEDURE
This tool is provided with a crimp ad ustment
feature. Initially, the crimp height should be
verified as specified in Figure 6. Refer to
Section 6, CRIMP HEIGHT INSPECTION, and
Section 7, RATCHET ADJUSTMENT, to verify
crimp height before using the tool to crimp
desired terminals or butt splices.
Refer to the table in Figure 1 and select wire of the
specified size. Strip the wire to the length indicated in
Figure 1, taking care not to nick or cut wire strands.
Select an applicable terminal or butt splice and
identify the appropriate crimping section according to
the wire size markings on the dies. Proceed as
follows:
1. Squeeze tool handles together until the ratchet
releases and then allow the tool jaws to open fully.
2. Hold the tool so that the back (wire side) is
facing you. See Figure 3.
3. Holding the wire barrel, insert the terminal or
butt splice into the appropriate crimping section so
that the wire barrel seam faces the wire crimper
and the edge of the wire barrel is even with the
edge of the wire crimper.
NOTE
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408-4372
PRO-CRIMPER III Hand Crimpin Tool Assembly 58508-1
3 of 5Rev B
Tyco Elec ronics Corpora ion
Back of Tool
(Wire Side)
Wire
Figure 3
4. Hold the terminal or butt splice in position and
squeeze the tool handles together until ratchet
engages sufficiently to hold the terminal or butt
splice in position. Do NOT deform the wire barrel.
5. Insert stripped wire into the wire barrel of the
terminal or butt splice as follows:
a. For terminals, make sure that the end of the
wire is even with the edge of the wire barrel and
wire crimper, as shown in Figure 4, Detail A.
b. For butt splices, make sure that the end of
the wire butts against the internal wire stop of
the splice, as shown in Figure 4, Detail B.
6. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped terminal or butt
splice.
The crimped terminal or butt splice may stick in
the crimping area; however, it can be easily
removed by pushing upward on the mating end of
the terminal or butt splice.
7. Inspect the crimped terminal or butt splice as
described in Section 5. Check the terminal or butt
splice crimp height as described in Section 6. If
necessary, adjust the crimp height as described in
Section 7, RATCHET ADJUSTMENT.
5. CRIMP INSPECTION
Inspect crimped terminals and butt splices by
comparing to the ones shown in Figure 5. Use only
the terminals and butt splices that meet the conditions
shown in the “ACCEPT” column. “REJECT” terminals
and butt splices can be avoided by carefully following
the above procedures and by performing regular tool
maintenance, as provided in Section 8,
MAINTENANCE AND INSPECTION.
6. CRIMP HEIGHT INSPECTION
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–height comparators. Detailed information on
obtaining and using crimp–height comparators can be
found in instruction sheet 408–7424.
Figure 4
S rip Leng h
Edge of Wire Even
wi h Edge of Terminal
Wire Barrel and Edge
of Wire Anvil
Wire Crimper
NOTE: No o Scale
S rip Leng h
Edge of Wire Bu s
Agains In ernal Wire
S op of Bu Splice
Wire Crimper
Detail A Detail B
NOTE
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408-4372
PRO-CRIMPER III Hand Crim ing Tool Assembly 58508-1
Rev B4 of 5 Tyco Electronics Corporation
ACCEPT REJECT
Wire Range
Stamped Under
Tongue
3
32
5
4
1
6
26
39
1
2
86
6
2
7
9
5
4
Wire Range
Stamped Under
Tongue
1Full length of terminal wire barrel is crimped. 1Full length of terminal wire barrel was not crimped (wire
barrel was not even with edge of die).
2Wire size is within range stamped on terminal or tongue or
butt splice. 2Wire size is not within wire range stamped on terminal tongue or butt splice.
3Wire fully inserted and acket does not enter wire barrel. 3Wire acket entered wire barrel of terminal or butt splice.
4Wire is flush with or extends slightly beyond end of terminal
wire barrel. 4End of conductor is not flush with or extending beyond end of terminal wire barrel (wire not fully inserted).
5Splices crimped by full width of dies. 5Full length of butt splice was not crimped (wire barrel was
not even with edge of die).
6Wire range stamped on die matches wire range stamped on
terminal or butt splice. 6Narrow and extruded wire barrel indicates die closure too small for terminal or butt splice and wire being used.
Compare wire ranges stamped on die and on terminal or
butt splice.
7Seam did not face wire crimper.
8Excessive flash indicates damaged dies.
9Nicked or missing conductor strands.
Figure 5
Proceed as follows:
1. Refer to Figure 6 and select a wire (maximum
size) for each crimping section listed.
2. Refer to Section 4, CRIMPING PROCEDURE,
and crimp the terminal(s) or butt splice(s)
accordingly.
3. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 6. 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,
RATCHET (Crimp Height) ADJUSTMENT.

408-4372
PRO-CRIMPER III Hand Crimping Tool Assembly 58508-1
5 of 5Rev B
Tyco Electronics Corporation
Position Point
on Center of
Wire Barrel
Opposite
Seam
A"
Modified Anvil
WIRE SIZE CRIMPING SECTION CRIMP HEIGHT
(AWG) (Max) (Wire Size Marking) DIMENSION A
16 22-16 1.85+0.05
[.073+.002
14 16-14 2.11+0.05
[.083+.002
10 12-10 3.71+0.05/-0.08
[.146+.002/-.003
Figure 6
7. RATCHET (Crimp Height) ADJ STMENT (Figure 7)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the front 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. Re–assemble the lockscrew.
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
Figure 7
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 AND INSPECTION
8.1. 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.
8.2. Visual Inspection
The crimping dies should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimping sections for flattened,
chipped, worn, or broken areas. If damage or
abnormal wear is evident, the tool must be replaced.
See Section 9, REPLACEMENT.
9. 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.
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
PO BOX 3608
HARRISBURG, PA 17105–3608
10. REVISION S MMARY
Revisions to this instruction sheet include:
S PRO–CRIMPER II Hand Tool became the
PRO–CRIMPER III Hand Tool
S TE logo was applied
S Format was updated to the current corporate
requirements