Tyco Electronics Pro-Crimper III Manual de usuario

Instruction Sheet

PRO-CRIMPER* III Hand Crimping

Tool Assembly 58583-1 with 408-4165

L C B

of 5

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

12 MAY 09 Rev A

Die Assembly 58583-2

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

applications. A wide selection of powered application equipment for extended-use, production operations is available.

Stationary

Jaw

Back of Tool

(Wire Side)

PR -CRIMPER III Hand

Crimping Tool Frame

354940-1 (408-9930)

Pivot

Stationary

Handle

Moving

Handle

Ratchet

Adjustment

Wheel

Moving

Jaw

Die Assembly

58583-2

Front of Tool

(Locator Side)

Locator Assembly

(Supplied with Die

Assembly)

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.

ire

Die Assembly TE

Locator Assembly

{

Contact

Family

}

Size

(mm2)

Insulation

Diameter

(mm [Inches])

Strip Length

(mm [Inches])

58583-2 58515-1 SUPERSEAL*

1.5 Series Contacts 0.5-1.5 1.70-2.40

[.067-.094] 3.00-3.50

[.118-.138]

{

Supplied with die assembly, also available separately.

}

Contact the Tooling Assistance Center or Product Information Center

(below) for specific contact part numbers.

Figure 1

1. INTRODUCTION

PRO–CRIMPER III Hand Crimping Tool Assembly

58583–1 consists of Die Assembly 58583–2 and

PRO–CRIMPER III Hand Crimping 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.

NOTE

408-4165

PRO-CRIMPER III Han Crimping Tool Assembly 58583-1

Rev

of 5 Tyco Electro ics Corporatio

Figure 2

Nut

Locator

Chamfer

Wire

Crimper

Offset

Wire A vil I sulatio

A vil Chamfer Die Retai i g

Screws

Die Retai i g

Pi s

Tool Frame

Locator

Assembly

I sulatio

Crimper

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 three

crimping chambers. 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, 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 OF DIE ASSEMBLY

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 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

408-4165

PRO-CRIMPER III Hand Cr mp ng Tool Assembly 58583-1

of 5Rev

Tyco Elect onics Co po ation

assembly, the two die retaining screws, and the

four die retaining pins, and slide the anvils and

crimpers out of the tool jaws.

4. CONTACT SUPPORT ADJUSTMENT

(Figu e 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. Int 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 and w re s zes.

Refer to the table in Figure 1 and select wire of the

specified size and insulation diameter. Assemble

applicable wire seal onto wire according to the

instructions packaged with the contact. 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 crimping chamber

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 crimping chamber.

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

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.

Figure 3

Adjustment

Sc ew fo

Contact

Suppo t

Contact

Suppo t Locato

Back of Tool

(Wi e Side)

Wi e

Contact

(Typ)

Locato in

Wi e Stop Slot Wi e

Inse ted

to Stop

St ip

Length

Wi e

Seal

Wi e

Seal

NOTE

408-4165

PRO-CRIMPER III Hand Crimping Tool Assembly 58583-1

R v

of 5 Tyco El ctronics Corporation

Make sure t at bot sides of t e insulation barrel

are started evenly into t e crimping c amber.

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 (with wire seal) 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 gages. However, TE recommends t e

modified micrometer (Crimp Heig t Comparator

RS-1019-5LP) or t e digital Mitutoyo

micrometer.

Proceed as follows:

1. Refer to Figure 4 and select a wire (maximum

size) for each crimping chamber 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

(Figur 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.

A"

+0.05

[+.002]

Position Point

on C nt r of

Wir Barr l

Opposit S am

Modifi d

Anvil

ire Size

(mm2)Crimping Chamber

( ire Size Marking) Crimp Height

Dimension a"

0.5 0.5 1.12 [.044]

1.0 1.0 1.30 [.051]

1.5 1.5 1.45 [.057]

Figure 4

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, secure the

lockscrew. If the dimension is unacceptable,

continue to adjust the ratchet, and again measure

a sample crimp.

Figure 5

Scr wdriv r

Ratch t

Adjustm nt

Wh l

Lockscr w

(Typ)

CAUTION

NOTE

408-4165

PRO-CRIMPER III Hand Crimpin Tool Assembly 58583-1

of 5Rev

Tyco 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 crimping chambers 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 1–717–986–7605, or write to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS

PO BOX 3608

HARRISBURG PA 17105–3608

11.REVISION SUMMARY

Since the previous release of this instruction sheet:

The TE logo was applied;

The PRO–CRIMPER II hand tool became the

PRO–CRIMPER III hand tool; and

The format was updated to the current

corporate requirements.

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