Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO-CRIMPER* III
Hand Tool Assembly 58560-1 408-4093
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
23 MAR 09 Rev A
and Die Assembly 58560-2
PROPER SE G IDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Figure 1
DIE ASSEMBLY
PART N MBER MOD LAR PL G
COND CTOR
SIZE
(AWG) INS L. DIA
(mm [IN.])
CABLE
O.D.
(mm [IN.]) STRIP LENGTH
(mm [IN.])
58560-2 10 Position
Modular Plug 28-24 AWG 7 Strand Wire .74 - .99 [.029 - .039] 5.46 [.215] 12.7 - 14.3 [.50 - .56]
Back of Tool
Pivot Pin
PR -CRIMPER III Hand Tool
Frame 354940-1 (See
Instruction Sheet 408-9930)
Stationary
Handle
Moving
Handle
Ratchet
Adjustment
Wheel
Moving Jaw
Die
Assembly
Front of
Tool
Stationary
Jaw
The PR -CRIMPER III 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 a variety of
tools to satisfy your performance requirements. For additional information,
contact the Tooling Assistance Center at 1-800-722-1111.
CERTI-CRIMP*
Ratchet
1. INTROD CTION
PRO–CRIMPER III Hand Tool Assembly 58560–1
consists of Die Assembly 58560–2, and hand tool
frame 354940–1. The die assembly consists of an
insulation stuffer, housing support, housing guides,
die retaining pins, and mounting hardware.
For additio al i formatio o the Modular
I terco ectio System, see Catalog 82066 or
co tact the Tech ical Assista ce Ce ter at
1-800-722-1111.
All dime sio s are i millimeters [with i ches i
brackets]. Figures a d illustratio s are for
ide tificatio o ly, a d are ot draw to scale.
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 insulation and
contact stuffers.
The die assembly features an insulation stuffer, a wire
stuffer, a housing support, housing guides, die
retaining pins, and die retaining screws which secure
the die set in the tool frame. Attached to the outside
of the frame are the housing guides. A nut is used on
the lower die retaining screw to secure the housing
guides in place.
NOTE
i
NOTE
i

408-4093
PRO-CRIMPER III Han Tool Assembly58560-1
Rev A2 of 4 Tyco Elect onics Co po ation
Figure 2
Tool F ame
Die Retaining
Pins
Die Retaining
Sc ews
Nut
Housing
Guide
Insulation
Stuffe
Wi e
Stuffe
Housing
Suppo t
Chamfe
Housing
Guide
3. DIE SET INSTALLATION AND REMOVAL (Figu e 2)
1. Close the tool handles until the ratchet releases,
and allow the handles to open fully. Remove the
nut and both die retaining screws from the tool
jaws.
2. Place the insulation/wire stuffer assembly as
shown in Figure 2. Insert short die retaining pins
and short die retaining screw through the tool
frame, and tighten the screw.
3. Place housing support in the moving jaw of the
tool frame as shown in Figure 2. Mount right hand
housing guide using long die retaining pins, and
secure with long die retaining screw. Mount left
hand housing guide and tighten nut.
4. To disassemble, close the tool handles until the
ratchet releases, remove nut, screws, housing
guides, retaining pins, housing support, and
insulation/wire stuffer assembly.
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 3. Refer to Sect on
5, CRIMP HEIGHT INSPECTION, and Sect on 6,
CRIMP HEIGHT ADJUSTMENT, to ver fy cr mp
he ght before us ng the tool to cr mp des red
connectors.
Before proceeding, Ensure that cable and plug are
compatible, and that cable polarity is correctly
maintained for your specific application.
Refer to Figure 1 and select cable of the specified
size and type. Strip the cable jacket to the length
indicated, taking care not to nick or cut wire
insulation. Proceed as follows:
1. Insert cable into plug until cable is fully
bottomed.
2. Hold the tool so that the back is facing you.
Squeeze the tool handles together and allow them
to open fully.
3. Insert plug assembly fully into die cavity until
plug bottoms in die cavity.
4. Squeeze handles until ratchet releases, and
remove terminated modular plug cable assembly.
5. Check the crimp height as described in Section
5, CRIMP HEIGHT INSPECTION. If necessary,
adjust the crimp height as described in Section 6,
CRIMP HEIGHT ADJUSTMENT.
5. CRIMP HEIGHT INSPECTION
Figure 3 shows a cutaway of a typical terminated plug
and the required location of the conductors. A visual
inspection through the plastic housing of the plug
should reveal whether the conductors are within the
acceptable range.
NOTE
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408-4093
PRO-CRIMPER III Han Tool Assembly58560-1
3 of 4Rev A
Tyco Electronics Corporation
Figure 3
Crimp Height
Dimension
6.02 + 0.13
[.237 + .005]
Modular Plug
Connector
(Cutaway View)
Conductor Location
0.64 [.025] Max
Contact
Stuffer
Housing
Support
Modular Plug
Connector
Ca le
Insulation
Stuffer
Inspect connector for proper crimp height using an
indicator with needle–point probes. Refer to Figure 3
for correct crimp height measurement. If necessary,
adjust the crimp height as described in Section 6,
CRIMP HEIGHT ADJUSTMENT.
6. CRIMP HEIGHT ADJUSTMENT (Figure 4)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the opposite 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 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, secure the
lockscrew. If the dimension is unacceptable,
continue to adjust the ratchet, and again measure
a sample crimp.
If correct crimp height cannot be obtained, tool and or
dies must be replaced See Section 8, PARTS
REPLACEMENT.
7. MAINTENANCE AND INSPECTION
7.1. Daily Maintenance
Tyco Electronics recommends that operators of the
tool be made aware of, and responsible for, the
following steps of daily maintenance:
1. Remove dust, moisture, and any other
contaminants from the tool with a clean, soft brush,
or a clean, soft, lint–free cloth. Do NOT use hard or
abrasive objects that could damage the tool.
Figure 4
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)

408-4093
PRO-CRIMPER III Hand Tool Assembly58560-1
Rev A4 of 4 Tyco Electronics Corporation
2. Make certain that the retaining pins are in place
and that they are secured with retaining rings.
3. All pins, pivot points, and bearing surfaces
should be protected with a thin coat of any good
SAE 20 motor oil. Do not oil excessively.
4. When the tool is not in use, keep handles closed
to prevent objects from becoming lodged in the
crimping jaws. Store the tool in a clean, dry area.
7.2. Periodi Inspe tion
Regular inspection of the tool should be performed by
quality control personnel. A record of scheduled
inspections should remain with the tool or be supplied
to supervisor personnel responsible for the tool.
Inspection frequency should be based upon amount
of use, working conditions, operator training and skill,
and established company standards.
7.3. Visual Inspe tion
The crimping dies should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimp sections for flattened,
chipped, worn, or broken areas. If damage or
abnormal wear is evident, the tool must be replaced.
See Section 8, PARTS REPLACEMENT.
1. Remove all lubrication and accumulated film by
immersing the tool (handles partially closed) in a
suitable commercial degreaser that will not affect
paint or plastic material.
2. Make certain that all retaining pins are in place
and secured with retaining rings.
3. Close tool handles until ratchet releases and
then allow them to open freely. If they do not open
quickly and fully, the spring is defective and must
be replaced. See Section 8, PARTS AND
REPLACEMENT.
4. Inspect the tool frame for wear or damage,
paying particular attention to the tool jaws and
pivot points. If damage is evident, refer to Section
8, PARTS REPLACEMENT. If tool is acceptable,
lubricate and return to service.
5. Check the crimping dies occasionally to make
sure dies are not broken or chipped. If damage is
evident, refer to Section 8, PARTS
REPLACEMENT.
8. PARTS 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:
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
9. REVISION SUMMARY
Since the previous release of this document, the TE
logo was changed.