Tyco Electronics PRO-CRIMPER III User manual

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Instruction Sheet
PRO-CRIMPER* III Hand Crimping
Tool Assembly 58603-1 with 408-4342
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 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
21 MAY 09 Rev A
Die Assembly 58603-2
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasional useandlowvolume
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 Assembly
(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 (408-9930)
Pivot Pin
Back of Tool
(Wire Side)
Stationary Jaw
Tool Marking (1)
ire
TE Die Assembly TE Locator Assembly
{ Contact FamilY }
Size (mm2)
(Color)
Insul Dia
(mm [in.])
Strip Length
(mm [in.])
2.5
(Yellow)
58603 2
58516 1
Junior Power
Timer and
1.5
(Blue) 1.4-2.1 3.1-3.9
58603
-
2
58516
-
1
Timer and
2.8mm Tab 1.0
(Red)
[.055-.083] [.122-.154]
0.75
(Green)
{ Supplied with die assembly, also available separately.
} Contact the Tooling Assistance Center or the Product Information Center at the numbers listed below for specific contact part numbers.
Figure 1
1. INTRODUCTION
PRO–CRIMPER III Hand Crimping Tool Assembly
58603–1 consists of Die Assembly 58603–2 and
PRO–CRIMPER III Hand Tool Frame 354940–1. 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.
Reason for revision can be found in Section 11,
REVISION SUMMARY.
NOTE
i

408-4342
PRO-CRIMPER III Han Crimping Tool Assembly 58603-1
Rev A2 of 5 Tyco Electro ics Corporatio
Figure 2
Nut
Locator
Assembly Tool Frame
Die Retai i g Pi s
Lo g Die Retai i g
Screw
Chamfer
I sulatio A vil
Wire A vil
Offset
Wire Crimper
Chamfer I sulatio
Crimper
Short Die Retai i g
Screw
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 four
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 tool frame is a locator
assembly, which contains a locator, a spring retainer,
and a contact support.
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 long 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 short 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 long 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 die retaining 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, while still allowing the locator to
slide up and down.
11. To disassemble, close the tool handles until the
ratchet releases, remove the nut, locator assembly,
the two die retaining screws, and the four die
retaining pins, and slide the anvils and crimpers out
of the tool jaws.

408-4342
PRO-CRIMPER III Hand Crimping Tool Ass mbly 58603-1
3 of 5Rev A
Tyco Electronics Cor oration
4. CONTACT SUPPORT ADJUSTMENT (Figure 3)
The contact support s preset pr or to sh pment,
but m nor adjustment may be necessary.
1. Make a sample crimp and determine if the
contact is straight, bending upward, or bending
downward.
2. If adjustment is required, loosen the screw that
holds the contact support onto the locator
assembly.
The ratchet has detents that create aud ble cl cks
as the tool handles are closed.
3. Place a contact with wire into the proper nest
and close the tool handles until the ratchet reaches
the sixth click, or until the contact support touches
the contact.
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
5. Move the contact support as required to
eliminate the bending of the contact.
6. Tighten the nut and close the handles until the
ratchet releases.
7. Remove and inspect the contact.
8. Make another sample crimp. If the contact is
straight, tighten the contact support screw. If the
contact is still being bent during crimping, repeat
the adjustment procedure.
5. CRIMPING PROCEDURE
Th s tool s prov ded w th a cr mp adjustment
feature. In t 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.
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.
Figure 3
Adjustment
Screw for
Contact
Su ort
Contact
Su ort Locator
Back of Tool
(Wire Side)
Wire
Contact
(Ty ) Stri Length
Wire Inserted
to Sto
Locator in Wire
Sto Slot
Not : Not to Scale
NOTE
i
NOTE
i
NOTE
i

408-4342
PRO-CRIMPER III Hand Crimping Tool Assembly 58603-1
Rev A4 of 5 Ty o Ele troni s Corporation
3. Position the contact so that the mating end of
the contact is on the locator side of the tool, and so
that the open “U” of the wire and insulation barrels
must face the top of the tool. Place the contact up
into the nest so that the movable locator drops into
the slot in the contact. Refer to Figure 3. Butt the
front end of the wire barrel against the movable
locator.
Make sure t at bot sides of t e insulation barrel
are started evenly into t e crimping section. 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. Insert stripped wire into contact insulation and
wire barrels until it is butted against the wire stop,
as shown in Figure 3.
6. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped contact.
T e crimped contact may stick in t e crimping
area, but t e contact can be easily removed by
pus ing downward on t e top of t e locator (see
Figure 3).
7. Check the contact crimp height as described in
Section 6, CRIMP HEIGHT INSPECTION. If
necessary, adjust the crimp height as described in
Section 7, CRIMP HEIGHT ADJUSTMENT.
6. CRIMP HEIGHT INSPECTION
This inspection requires the use of a micrometer with
a modified anvil.
Tyco Electronics does not manufacture or market
t ese micrometers. However TE recommends t e
modified micrometer (Crimp Heig t Comparator
RS-1019-5LP) or t e digital micrometer from
Mitutoyo.
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
2. Refer to Section 5, 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
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.
Position Point
on Center of
Wire Barrel
Opposite
Seam
A"
Modified Anvil
IRE SIZE CRIMP SECTION CRIMP HEIGHT
DIMENSION A
mm2(Max) (Color Marking)
DIMENSION A
(+0.05 [+.002])
2.5 Yellow 1.88 [.0740]
1.5 Blue 1.58 [.0621]
1.0 Red 1.36 [.0535]
0.75 Green 1.27 [.0500]
Figure 4
7. RATCHET (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. Re–assemble 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.
CAUTION
!
NOTE
i
NOTE
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408-4342
PRO-CRIMPER III Hand Crimping Tool Ass mbly 58603-1
5 of 5Rev A
Tyco Electronics Corporation
Figure 5
Scre driver
Ratchet
Adjustment
Wheel
Lockscre
(Typ)
9. VISUAL INSPECTION
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 10, REPLACEMENT.
10. 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 CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
11.REVISION SUMMARY
Since the previous release of this instruction sheet,
the following changes have been made:
S PRO–CRIMPER II Hand Tool became the
PRO–CRIMPER III Hand Tool;
S The TE logo was applied; and
S The format was updated to the current
corporate requirements.