Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand
Crimping Tool Assembly 58525- 1 408--9994
LOC B
1of 5
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
21 SEP 09 Rev Bwith Die Assembly 58525- 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.
Front of Tool
(Locator Side)
Die
Assembly
Moving Jaw
Ratchet
Adjustment
Wheel
Stationary Jaw
Back of Tool
Wire Side)
Pivot Pin
PRO--CRIMPER III Hand
Crimping Tool Frame
354940--1 (408--9930)
Stationary
Handle
Moving Handle
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. 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.
T
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Wire
T
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Assembly
T
erm
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Family}Size
(AWG) Insul Dia Strip Length (mm [In.])
5
8
5
2
5
-
-
2
.250 Series
F
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T
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N
*
14--12 3.81 to 5.08 6.40
5
8
5
2
5
--
2
F
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*
Receptacle 10
3
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8
1
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5
.
0
8
[.150 to .200]
6
.
4
0
[.252]
}CALL THE TOOLING ASSISTANCE CENTER OR PRODUCT INFORMATION (SEE BELOW) FOR PRODUCT PART NUMBERS.
Figure 1
1. INTRODUCTION
PRO--CRIMPER III Hand Crimping Tool
Assembly 58525--1 consists of Die Assembly
58525--2 and PRO--CRIMPER III Hand Crimping Tool
Frame 354940--1. The die assembly consists of wire
and insulation crimping dies..
Read these instructions thoroughly before crimping
any terminals
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.
NOTE
i

408- 9994
PRO- CRIMPER III Hand Crimping Tool Assembly 58525- 1
Rev B2 of 5 Tyco Electronics Corporation
Figure 2
Chamfer
Wire Crimper
Wire Anvil
Insulation
Anvil
Insulation
Crimper
Tool Frame
Die Retaining
Pins
Die Retaining
Screws
Chamfer
2. DESCRIPTION (Figures 1 and 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.
Die retaining pins and die retaining screws are used
to position and secure the dies in the tool frame.
3. INSTALLATION AND REMOVAL OF
DIE SET (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 a 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 a 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. To disassemble, close the tool handles until the
ratchet releases, remove the two die retaining
screws and the four die retaining pins, and slide
the anvils and crimpers out of the tool jaws.
4. 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 5, CRIMP HEIGHT INSPECTION, and
Section 6, RATCHET (Crimp Height)
ADJUSTMENT, to verify crimp height before
using the tool to crimp desired terminals 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 terminal
and identify the appropriate crimp section according
to the wire size markings on the tool. Refer to
Figure 3 and proceed as follows:
NOTE
i

408- 9994
PRO- CRIMPER III Hand Crimping Tool Assembly 58525- 1
3of 5Rev BTyco Electronics Corporation
Figure 3
Back of Tool
(Wire Side)
Wire
Front of Wire Barrel
Even with the Edge
of the Wire Crimper
Wire Crimper
Strip Length
Wire Barrel
Terminal (Typ)
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 terminal by the mating end, insert
the terminal — insulation barrel first — through the
front of the tool and into the appropriate crimp
section.
3. Position the terminal so that the mating end of
the terminal is on the front side of the tool, and so
that the open “U” of the wire and insulation barrels
face the top of the tool. Place the terminal up into
the nest.
Make sure that both sides of the insulation barrel
are started evenly into the crimping section. Do
NOT attempt to crimp an improperly positioned
terminal.
4. Rotate the tool sufficiently to be able to view the
front side of the wire crimper, and position the
terminal so that the front edge of the wire barrel is
even with the front edge of the wire crimper, as
shown in Figure 3.
5. Hold the terminal in position and squeeze the
tool handles together until ratchet engages
sufficiently to hold the terminal in position. Do NOT
deform insulation barrel or wire barrel.
6. Rotate the tool so that the back (wire side) is
once again facing you.
7. Insert stripped wire into terminal insulation and
wire barrels until the end of the wire is even with
the edge of the wire barrel and wire crimper, as
shown in Figure 3.
8. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped terminal.
The crimped terminal may stick in the crimping
area, but the terminal can be easily removed by
pushing downward on the mating end of the
terminal.
9. Check the terminal’s crimp height as described
in Section 5, CRIMP HEIGHT INSPECTION. If
necessary, adjust the crimp height as described in
Section 6, RATCHET (Crimp Height)
ADJUSTMENT.
5. 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,
RATCHET ADJUSTMENT.
CAUTION
!
NOTE
i

408- 9994
PRO- CRIMPER III Hand Crimping Tool Assembly 58525- 1
Rev B4 of 5 Tyco Electronics Corporation
Position Point
on Center of
Wire Barrel
Opposite
Seam
“A”
Modified Anvil
Wire Size Crim
p
Section Crimp Height
D
i
m
e
n
s
i
o
n
A
a
n
d
W
i
r
e
S
i
z
e
AWG (Max)
C
r
i
m
p
S
e
c
t
i
o
n
(Wire Size Marking) Dimension A and
Tolerance (+)
12 14--12 2.16 + .005
[.085 + .002]
10 10 2.87 + .05
[.113 + .002]
Figure 4
6. 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 front 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)
7. 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. 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 9, REPLACEMENT.
9. REPLACEMENT
Customer--replaceable parts are shown in Figure 1.
Available separately, 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
Revisions to this instruction sheet include:
SChanged PRO--CRIMPER II Hand Tool to
PRO--Crimper III Hand Tool;
SRevised Crimp--Height Inspection section;
SUpdated format to current corporate
requirements;
SApplied TE logo; and
SAdded back page illustrating tooling available
for dies 58525--2.

408- 9994
PRO- CRIMPER III Hand Crimping Tool Assembly 58525- 1
5of 5Rev BTyco Electronics Corporation
PRO-CRIMPER III Hand Tool 354940- 1
(Instruction Sheet 408-9930)
SDE PEW- 12 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 58525- 2 Can Be Used In the Following Tools: