Tyco Electronics PRO-CRIMPER II User manual

Instruction Sheet

PRO–CRIMPER* II

Hand Tool Assembly 58546–1 408–4047

2003 Tyco Electronics Corporation, Harrisburg, PA

AllInternationalRightsReserved

AMP and Tyco are trademarks. *Trademark

Other products, logos, and company names used are the property of their respective owners. LOC B

1 of 5

TOOLINGASSISTANCE CENTER 1–800–722–1111

FAX/PRODUCTINFO1–800–522–6752

For Regional Customer Service, visit our website at

www.tycoelectronics.com

This controlled document is subject to change.

For latest revision, call the FAX/PRODUCT INFO number.

24 OCT 03 Rev D

with Die Assembly 58545–1

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

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

The PRO–CRIMPER II Hand 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 avariety of

tools to satisfy your performance requirements. For additional information,

contact the Tooling Assistance Center at 1–800–722–1111.

Front of Tool

DieAssembly

MovingJaw

RatchetAdjustment

Wheel

Moving

Handle

Stationary

Handle

PRO–CRIMPER II Hand Tool

Frame354940–1

(SeeInstruction

Sheet408–9930)

Pivot Pin

Back of Tool

(WireSide)

StationaryJaw

WIRE

DIE ASSEMBL

PRODUCT

FAMILY

}

SIZE

(AWG) STRIP LENGTH

(mm [in.])

58545–1 SOLISTRAND* Butt Splice 22–10 6.35–7.14 [.25–.281]

}

Contact the Tooling Assistance Center at the number listed below for specific splice part numbers.

Figure 1

1. INTRODUCTION

PRO–CRIMPER II Hand Tool Assembly 58546–1

consists of Die Assembly 58545–1 and

PRO–CRIMPER II Hand Tool Frame 354940–1. The

tool is used to crimp the splices onto the wire size

listed in Figure 1.

Read these instructions thoroughly before crimping

any splices.

Dimensions on this sheet are in millimeters [with

inchequivalents provided in brackets].

Reasons for reissue of this instruction sheet are

provided in Section 10, 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 crimping.

The tool frame holds a die assembly with three

crimping chambers. The die assembly features an

upper die and a lower die. Die retaining screws are

used to position and secure the dies in the tool frame.

NOTE

408–4047

PRO–CRIMPER II Hand Tool Assembly 58546–1

Rev D2 of 5

Figure 2

UpperDie

LowerDie

Indenters Anvils

DieRetaining

Screws

StationaryJaw

3. DIE ASSEMBLY INSTALLATION AND REMOVAL

1. Open the tool handles and remove the two die

retaining screws from the tool jaws.

2. Place the upper die in the stationary jaw of the

tool frame so that the largest indenter is facing

inward. See Figure 2.

3. Insert the die retaining screw through the

stationary jaw and through the die. Tighten the

screw just enough to hold the die in place. Do

not

tighten the screw completely at this time.

4. Place the lower die in the moving jaw of the tool

frame so that the largest anvil is facing inward. See

Figure 2.

5. Insert the die retaining screw through the

moving jaw and through the die. Tighten the screw

just enough to hold the die in place. Do

not

tighten

the screw completely at this time.

6. Carefully close the tool handles, making sure

that the anvils and indenters align properly.

Continue closing the tool handles until the ratchet

has engaged sufficiently to hold the dies in place,

then tighten both die retaining screws.

7. To disassemble, open the tool handles until the

ratchet releases, remove the two die retaining

screws, and slide the dies out of the tool jaws.

4. CRIMPING PROCEDURE

Before using the tool, the crimping chambers and

tool ratchet should be inspected as specified in

Section 5, CRIMP HEIGHT INSPECTION, and

Section6,SHUTHEIGHTADJUSTMENT.

Refer to Figure 1 and select wire of the specified size

and insulation diameter. Strip the wire to the length

indicated, taking care not to nick or cut wire strands.

Select an applicable splice and identify the

appropriate crimping chamber according to the wire

size markings on the dies. Refer to Figure 3 and

proceed as follows:

1. Hold tool so that the back (wire side) is facing

you. Squeeze tool handles together until the

ratchet releases, then allow them to open fully.

2. Center the splice wire barrel on the anvil of the

upper die as shown in Figure 3. If visible, be sure

to place the brazed seam on the splice toward the

indenter.

3. Hold the wire barrel in place and squeeze the

tool handles together until ratchet engages

sufficiently to hold the splice in position. Do NOT

deform the insulation barrel or wire barrel.

4. Insert stripped wire into the wire barrel, making

sure that the insulation does not enter the wire

barrel. See Figure 3.

5. Holding wire in place, squeeze tool handles

together until ratchet releases. Allow tool handles

to open, then remove crimped splice.

NOTE

408–4047

PRO–CRIMPER II Hand Tool Assembly 58546–1

3of 5Rev D

Figure 3

Splice Wire Barrel

Centered on Anvil of

LowerDie

BrazedSeam

PositionedToward

Indenter

6. To crimp the other half of a splice, reposition the

uncrimped wire barrel in the crimping chamber, and

repeat the crimping procedure.

If splice cannot be turned for crimping the other

half, turn the tool around.

7. Inspect the crimped splice according to

Figure 4. Check the crimp height as described in

Section 5. If necessary, adjust the shut height as

described in Section 6.

Damaged splices may not be used. If a damaged

splice is evident, it must be replaced with a new

one.

Figure 4

InspectionHole

Crimp is centered on wire barrel. It is acceptable for

crimp to be slightly off center, but NOT OFF THE END of

the wire barrel.

Wire size being used matches wire size range stamped

on splice and dies.

Wire insulation does not enter wire barrel.

Wire is flush with or extends slightly beyond end of wire

barrel. Wire is visible through inspection hole of splices.

NOTE CAUTION

408–4047

PRO–CRIMPER II Hand Tool Assembly 58546–1

Rev D4 of 5

5. CRIMP HEIGHT INSPECTION

This inspection requires the use of plug gages

conforming to the dimensions provided in Figure 5.

Tyco Electronics does not manufacture or market

these gages. To gage the crimping chamber, proceed

as follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gage.

2. Close the tool handles until the dies have

bottomed. Do NOT force dies beyond initial

contact.

3. Align the GO element with the crimping

chamber. Push element straight into the crimping

chamber without using force.

Suggested Plug Gage Design

DieClosure

Configuration

“R”

12.7[.50]

Min Typ

Dim.

50.8[2.00]

Min Typ

“R”

NO–GO

Dim.

CRIMPING GAGE ELEMENT DIMENSIONS

CHAMBER

(Die Marking) GO NO–GO “R”

(Radius)

22–18 1.143–1.151

[.0450–.0453] 1.344–1.346

[.0529–.0530] 1.57 [.062]

16–14 1.346–1.354

[.0530–.0533] 1.547–1.549

[.0609–.0610] 1.98 [.078]

12–10 1.905–1.913

[.0750–.0753] 2.106–2.108

[.0829–.0830] 2.77 [.109]

Figure 5

NO–GO Element May Start Entry, But Must Not

PassCompletely Through Crimping Chamber

GO Element Must Pass Completely

ThroughCrimping Chamber

The GO element must pass completely through the

crimping chamber. See Figure 5.

4. Align the NO–GO element and try to insert it

straight into the same crimping chamber. The

NO–GO element may start entry, but must not

pass completely through the crimping chamber.

See Figure 5.

If the crimping chamber conforms to the gage

inspection, the tool is considered dimensionally

correct, and should be lubricated with a THIN coat of

any good SAE 20 motor oil. If not, the tool must be

returned to Tyco Electronics for further evaluation and

repair. Refer to Section 8, REPLACEMENT.

For additional information regarding the use of a plug

gage, refer to instruction sheet 408–7424.

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew

Figure 6

6. SHUT HEIGHT ADJUSTMENT (Figure 6)

The frame assembly ratchet mechanism features an

adjustment wheel with numbered settings. If the dies

do not bottom, adjust the ratchet as follows:

1. Remove the lockscrew from the ratchet

adjustment wheel.

2. With a screwdriver, adjust the ratchet wheel

from the opposite side of the frame.

3. Observe the ratchet adjustment wheel. If the

dies do not bottom, rotate the adjustment wheel

COUNTERCLOCKWISE to a higher–numbered

setting.

4. Replace the lockscrew.

408–4047

PRO–CRIMPER II Hand Tool Assembly 58546–1

5of 5Rev D

7. MAINTENANCE AND INSPECTION

7.1. 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.

7.2. Visual Inspection

The die assembly 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 or dies must be

replaced. See Section 8, REPLACEMENT.

8. REPLACEMENT

Customer–replaceable parts are shown in Figure 1.

Available separately, PRO–CRIMPER II 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

For tool repair service, please contact a Tyco

Electronics Representative at 1–800–526–5136.

9. STANDARD SOLISTRAND TERMINALS

To crimp standard SOLISTRAND terminals and

parallel splices, refer to Instruction Sheet 408–8678.

10. REVISION SUMMARY

Revisions to this instruction sheet per

EC 0990–1181–03 include:

Updated document to corporate requirements

Added markings to dies in Figure 2

Changed wire size range from 22–16 to 22–18

in table in Figure 5

This manual suits for next models

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