Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO-CRIMPER* III Hand Crimping
Tool Assembly 58541-1 408-4051
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
28 APR 09 Rev B
with Die Assembly 58541-2
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 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 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 Technical Assistance Center at
1-800-722-1111.
Front of Tool
(Locator Side)
Ratchet
Adjustment
Wheel
Back of Tool
(Wire Side)
Pivot Pin
Moving Jaw
Moving Handle
Stationary
Handle
Die
Assembly
Stationary Jaw
PR -CRIMPER III Hand
Crimping
Tool Frame 35494-1 (See
instruction sheet 408-9930)
Die Assembly
Locator Assembly
Contact
Wire
Die Assembly
Part Number
Locator Assembly
Part Number {
Contact
Family }
Size
(AWG) Insulation Diameter
(mm [In. ) Strip Length (mm [In. )
58541-2
189382-1
67 MULTIMATE*
Type II Series
24-22 1.40 to 2.16
[.055 to .085] 5.32 [.209]
58541
-
2
189382
-
1
Type II Series
Contacts 18-14 PEN 6.35
[.250]
{ Supplied with the die assembly. Also available separately. } Contact the Product Information Center (below) for specific contact part numbers.
Figure 1
1. INTRODUCTION
PRO–CRIMPER III Hand Crimping Tool
Assembly 58541–1 consists of Die Assembly
58541–2 and PRO–CRIMPER III Hand Crimping Tool
Frame 354940–1. The die assembly consists of
crimping dies and a locator assembly. Refer to
Figure 1.
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.
NOTE
i

408-4051
PRO-CRIMPER III Hand Crimping Tool Ass mbly 58541-1
Rev B2 of 4 Tyco Electro ics Corporatio
Figure 2
Nut Locator
Assembly
Wire Crimper
Wire A vil
I sulatio
Crimper
I sulatio
A vil
Die Retai i g
Pi s
Die Retai i g
Screws
Tool Frame
Chamfer
Chamfer
Offset
Locator
Reasons for reissue are provided in Section 10,
REVISION SUMMARY.
2. DESCRIPTION (Figure 1 a d Figure 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 two
crimping sections.
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
assembly.
Die retaining pins and die retaining screws are used
to position and secure the dies in the tool frame. A
nut is used on the lower die retaining screw to hold
the locator assembly 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 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 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 assembly over the end of the
long screw, and position the locator assembly
against the side of the tool jaw.
10. Place the nut onto the end of the long screw
and tighten the nut enough to hold the locator
assembly in place.
11. To disassemble, close the tool handles until the
ratchet releases, remove the nut, the locator
assembly, the two die retaining screws, and the
four die retaining pins, and slide the anvils and
crimpers out of the tool jaws.

408-4051
PRO-CRIMPER III Hand Crimping Too Assemb y 58541-1
3 of 4Re B
Tyco Electronics Corporation
Figure 3
Wire
Inserted
in Contact
Strip
Length
Contact (Typ)
Back of Tool
(Wire Side)
Wire
Locator
Contact
Shoulder
Against
Locator
4. CRIMPING PROCEDURE
This tool is provided with a crimp adjustment
feature. Initially, the crimp height should e
verified as specified in Figure 4. Refer to
Section 5, CRIMP HEIGHT INSPECTION, and
Section 6, CRIMP HEIGHT ADJUSTMENT, to
verify crimp height efore using the tool to crimp
desired contacts and wire sizes.
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 crimp section according
to the wire size markings on the tool. 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 mating end, insert
the contact — insulation barrel first — through the
front of the tool and into the appropriate crimp
section.
3. Position the contact so that the mating end of
the contact is on the locator side of the tool. Refer
to Figure 3. Butt the contact shoulder against the
locator.
Do NOT attempt to crimp an improperly
positioned contact.
4. 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.
5. Fully insert the stripped wire into the contact as
shown in Figure 3.
6. While holding the wire in place, squeeze the tool
handles together until ratchet releases. Allow the
tool handles to open, and remove the crimped
contact.
7. Check the contact’s 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
This inspection requires the use of a micrometer with
a modified anvil.
Tyco Electronics does not manufacture or market
these gages. Hovever, TE recommends the
modified micrometer (Crimp Height Comparator
RS-1019-5LP) .
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
2. Refer to Section 4, 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
NOTE
i
CAUTION
!
NOTE
i

408-4051
PRO-CRIMPER III Hand Crimping ool Assembly 58541-1
Rev B4 of 4 Ty o Ele troni s Corporation
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 6,
CRIMP HEIGHT ADJUSTMENT.
Figure 4
WIRE SIZE
AWG (MAX) CRIMP SEC ION
(WIRE SIZE MARKING)
CRIMP HEIGH
DIM. (A) AND
OLERANCE (+)
Position
Point on
Center of
Wire Barrel
Opposite the
Seam
Modified
Anvil
A"
20
14
20-24
18-16-14
1.09 " .051
[.043 " .002]
160 " .051
[.063 " .002]
6. CRIMP HEIGH ADJUS MEN (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.
7. MAIN ENANCE
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.
Figure 5
S rewdriver
Rat het
Adjustment
Wheel
Lo ks rew
(Typ)
8. VISUAL INSPEC ION
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 9, REPLACEMENT.
9. REPLACEMEN
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
1–717–986–7605, or write to:
CUSTOMER SERVICE 38–35
TYCO ELECTRONICS
PO BOX 3608
HARRISBURG PA 17105–3608
10. REVISION SUMMARY
Since the previous release of this document:
S The TE logo was applied;
S The PROCRIMPER II Hand Tool became the
PRO–CRIMPER III Hand Tool; and
S The format of the sheet was updated to the
current corporate requirements.