Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand Crimping
Tool Assembly 58530- 1 with 408--4005
LOC B
1of 6
E2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 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
10 NOV 09 Rev CDie Assembly 58530- 2
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume
applications. A wide selection of powered application equipment for extended--use, production operations is available.
Stationary Jaw
Back of Tool
(Wire Side)
Pivot Pin
PRO--CRIMPER III Hand
Crimping Tool Frame
354940--1 ( 408--9930)
Ratchet Adjustment Wheel
Moving Jaw
Die Assembly
Front of Tool
(Locator Side)
Locator Assembly
(Supplied with
Die Assembly)
The PRO--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 series specification, but may not comply with other feature parameters of the specification. A variety of tools is offeredto
satisfy your performance requirements. For additional information, contact the Tooling Assistance Center at 1--800--722--1111.
C
o
n
t
a
c
t
Wire
TE Die Assembly Locator Assembly{Contact
Family}Size
(AWG)
Insul
Dia
Strip Length
(mm [in.])
5
8
5
3
0
2
5
8
5
1
6
1
Universal
M
A
T
E
N
L
O
K
*
12
5
0
8
[
2
0
0
]
M
a
x
6.35 to 7.05
58530--2 58516--1 M
A
TE--N--LOK
*
Connectors 10
5.08 [.200
]
Max
6
.
3
5
t
o
7
.
0
5
[.250 to .281]
{Supplied with die assembly. Also available separately..
}Contact the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION (see below) for specific contact part numbers.
Anvil must be reversed when changing from one wire size to the other
Figure 1
1. INTRODUCTION
PRO--CRIMPER III Hand Tool Assembly 58530--1
consists of Die Assembly 58530--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.
Reasons for reissue of this document are provided in
Section 11, REVISION SUMMARY.
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 contact crimping.
The tool frame holds a die assembly with two
crimping sections.
The die assembly features an anvil and a crimper.
NOTE
i

408- 4005
PRO- CRIMPER III Hand Crimping Tool Assembly 58530- 1
Rev C2 of 6 Tyco Electronics Corporation
Figure 2
Locator
Assembly
Nut
Locator
Tool Frame
Die Retaining Pins
Die Retaining
Screws
No. 12
Wire Size
Anvil
Chamfer
Crimper
Chamfer
(Shown for No. 12 wire.
Reverse anvil for No. 10 wire.)
No. 10
Wire Size
Attached to the outside of the 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 upper die retaining screw to hold
the locator assembly in place.
3. INSTALLATION AND REMOVAL OD 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 anvil in the moving jaw. The rear nest
is used to crimp the terminal — make sure that the
anvil is positioned so that the correct wire size
marking is located at the rear crimping area.
The anvil die must be reversed to accommodate
the use of either 12 or 10 AWG wire.
3. Insert the two die retaining pins.
4. Insert the short die retaining screw through the
jaw and through the anvil die, and tighten the
screw just enough to hold the die in place. Do not
tighten the screw completely at this time.
5. Place the crimper die in the stationary jaw of the
tool. Make sure that the chamfered end of the die
faces outward.
6. Insert the two die retaining pins.
7. Insert the long die retaining screw through the
jaw and through the crimper die, and tighten the
screw just enough to hold the die in place. Do not
tighten the screw completely at this time.
8. Carefully close the tool handles, making sure
that the dies align properly. Continue closing the
tool handles until the ratchet in the tool frame has
engaged sufficiently to hold the dies 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, while still allowing the locator to
slide up and down.
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 dies out of the
tool jaws.
4. CONTACT SUPPORT ADJUSTMENT (Figure 3)
The contact support is preset prior to shipment,
but minor adjustment may be necessary.
NOTE
i
NOTE
i

408- 4005
PRO- CRIMPER III Hand Crimping Tool Assembly 58530- 1
3of 6Rev CTyco Electronics Corporation
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 audible clicks
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
This tool is provided with a crimp adjustment
feature. Initially, the crimp height should be
verified as specified in Figure 4. Refer to
Section 6, CRIMP HEIGHT INSPECTION, and
Section 7, RATCHET (Crimp Height)
ADJUSTMENT, to verify crimp height before
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, and so
that the open “U” of the wire barrel faces 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.
Figure 3
Back of Tool
(Wire Side)
Wire
Locator
Contact
Support
Adjustment
Screw for
Contact
Support
Contact (Typ)
Strip
Length
Locator in
Wire Stop Slot Wire Inserted
to Stop
NOTE
i
NOTE
i

408- 4005
PRO- CRIMPER III Hand Crimping Tool Assembly 58530- 1
Rev C4 of 6 Tyco Electronics Corporation
Make sure that both sides of the wire barrel are
started evenly into the 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.
5. Insert stripped wire into the contact until the wire
butts 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.
The crimped contact may stick in the crimping
area, but the contact can be easily removed by
pushing downward on the top of the locator
(see Figure 3).
7. 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, RATCHET (Crimp Height)
ADJUSTMENT.
Figure 4
Wire Size
AWG (Max)
Crimp Section
(Wire Size Marking)
Crimp Height
Dim. (A) and
Tolerance (+)
“A”
12
10
12
10
2.11 .05
[.083 .002]
2.44 .05
[.096 .002]
Position Point
on Center of
Wire Barrel
Opposite
Seam
Modified
Anvil
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.
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.
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. 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.
Figure 5
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)
CAUTION
!
NOTE
i

408- 4005
PRO- CRIMPER III Hand Crimping Tool Assembly 58530- 1
5of 6Rev CTyco Electronics Corporation
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. 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 AND REPAIR.
10. REPLACEMENT AND REPAIR
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 CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
For tool repair service, please contact a
representative at 1--800--526--5136.
11. REVISION SUMMARY
Revisions to this instruction sheet include:
SPRO--CRIMPER II Hand Tool became the
PRO--CRIMPER III Hand Tool;
SCrimp height adjustment information was
revised;
STE logo was applied;
SFormat was updated; and
SThe back page was added to illustrate tooling
compatible with Dies 58530--2.

408- 4005
PRO- CRIMPER III Hand Crimping Tool Assembly 58530- 1
Rev C6 of 6 Tyco Electronics Corporation
PRO- CRIMPER III Hand Tool 354940-1
(Instruction Sheet 408-9930)
SDE- SA Hand Tool 9-1478240- 0
(Instruction Sheet 408-8851)
SDE Bench Terminator 1490076-2
(Customer Manual 409- 10052)
626 Adapter 679304- 1
(Instruction Sheet 408-4070)
Battery Tool (Shouldered Die) 1725837- 1, -2
(Customer Manual 409- 10053)
Battery Tool (Pin Die) 1213890- 1, -2
(Customer Manual 409- 10065)
Die Assembly 58530- 2 Can Be Used In:

Mouser Electronics
Authorized Distributor
Click to View Pricing, Inventory, Delivery & Lifecycle Information:
TE Connectivity:
58530-1 58530-2