Tyco Electronics PRO-CRIMPER III User manual

Instruction Sheet

PRO-CRIMPER* III Hand Tool Assem ly

58573-1 with Crimping Die Assem ly 408-4251

2005 Tyco Electronics Corporation, Harrisburg, A

All International Rights Reserved

AM and Tyco are trademarks. *Trademark

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

of 4

TOOLING ASSISTANCE CENTER 1-800-722-1111

RODUCT INFO 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

07 A R 05 Rev C

58573-2 for Spare Wire Caps

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume

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

Figure 1

Die Retaining

Screws

RO-CRIM ER* III

Hand Tool Frame

354940-1

Die Assembly

58573-1

Stationary Jaw

Moving Jaw

Ratchet

Adjustment

Wheel

Stationary

Handle

Moving

Handle

1. INTRODUCTION

This instruction sheet covers the use of

PRO–CRIMPER III Hand Tool 58573–1 with Crimping

Die Assembly 58573–2, which is used to apply the

standard and moisture resistant spare wire caps listed

in Figure 2. The die assembly is designed to be used

in PRO–CRIMPER III Hand Tool Frame 354940–1

(shown in Figure 1). For instructions concerning the

operation of the hand tool, refer to Instruction Sheet

408–9930, which is supplied with the tool.

Measurements are in millimeters [followed by

inch equivalents in brackets].

Reasons for reissue of this document are provided in

Section 8, REVISION SUMMARY.

2. DESCRIPTION

(Figure 1)

Each die assembly consists of an indenter die and an

anvil die. When closed, the dies form four crimping

chambers, which coincide with the four sizes of spare

wire caps. Die retaining screws are used to secure

the dies in the tool frame.

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.

For Single Unstripped

Wire (Thin Copper Insert)

With or Without Moisture-

Resistant Inhibitor

WIRE

INSUL

SPARE WIRE CAP No's CAP TOOL

COLOR

INSUL

DIA.

RANGE STANDARD MOISTURE

RESISTANT

COLOR

CODE

COLOR

CODE

DOT

1.22 - 1.91

[.048 - .075] 324484 324693 WHITE WHITE

2.03 - 2.92

[.080 - .115] 324485 324694 RED RED

3.05 - 3.68

[.120 - .145] 324486 324695 BLUE BLUE

3.81 - 5.33

[.150 - .210] 324487 324696 YELLOW YELLOW

Figure 2

NOTE

408-4251

PRO-CRIMPER III Hand Too Assemb y 58573-1

R v

of 4

Figure 3

Tool Jaws

(R f)

Di Ass mbly

PRO-CRIMPER II

Hand Tool Fram

Ass mbly 354940-1

R taining

Scr ws

Ind nt r

Anvil

3. DIE INSTALLATION

1. Close the tool handles until the ratchet releases,

then allow the handles to open fully.

2. Insert the dies into the tool jaws as shown in

Figure 3, and align the die retaining holes in each

die with the associated holes in the tool.

3. Thread, but do not tighten, the die retaining

screws into the holes.

4. Carefully close the tool handles, making sure

that the dies align properly.

5. Tighten the die retaining screws.

4. CRIMPING PROCEDURE

1. Refer to Figure 2, and select a cap of the

correct size for the insulation diameter of the wire

being used.

2. Identify the color code of the cap, and insert the

cap into the crimping chamber with the same color

code. Be sure that the cap is fully inserted.

3. Begin closing the tool handles until the cap is

held firmly in place. Do NOT deform the cap.

4. Insert the unstripped wire completely into the

cap.

When bottoming the wire in a moisture-resistant

cap, greater insertion force must be exerted on

the wire to displace the inhibitor present in the

cap.

5. Close the tool handles until the ratchet releases.

6. Allow the tool handles to open FULLY and

remove the crimped cap from the crimping

chamber by turning the cap and wire 1/4 turn while

pulling lightly on the wire.

Damaged products may not be used. If a

damaged product is evident, it must be replaced.

5. CRIMP INSPECTION

(Figur 4)

Inspect the crimped spare wire cap. The crimp should

be near the center of the insert in the cap, and the

wire should be bottomed in the cap.

Double check that the correct cap was used for the

wire’s insulation diameter, and make sure that the

correct crimping chamber was used.

If the cap fails inspection, remove the cap by cutting

the wire, then apply a new cap to the wire by carefully

following the above procedure.

Figure 4

Wir bottom d in cap.

1Crimp n ar c nt r of ins rt. (Cap was fully bottom d in

di closur .)

2Corr ct wir insulation diam t r for cap

b ing us d.

4Cap insulation color match s di closur color dot cod .

NOTE

CAUTION

408-4251

PRO-CRIMPER III Hand Tool Assembly 58573-1

of 4Rev

HAND TOOL AND DIE

ASSEMBLY

DIE OPENING +0.10 .004]

ASSEMBLY

PART NUMBERS AB C D

58573-1

58573-2 1.83 [.072] 2.26 [.089] 2.95 [.116] 3.61 [.142]

Figure 5

6. MAINTENANCE AND INSPECTION

6.1. Maintenance

1. Remove dust, moisture, and other contaminants

with a clean, soft brush, or a clean, soft, lint–free

cloth. Do NOT use any objects that could damage

the dies or tool.

2. Make sure that the proper die retaining screws

are properly secured.

3. When the dies are not in use, store them in a

clean, dry area. When the tool is not in use, store it

with the handles closed to prevent objects from

being lodged within the jaws.

6.2. Inspection

1. Remove all lubrication and accumulated film

from the dies by immersing the dies in a suitable

commercial degreaser.

2. Make certain that all die retaining screws and

die components are properly secured.

3. Inspect the crimping surfaces for flattened,

chipped, worn, or cracked areas. If damage is

evident, the dies must be replaced. Refer to

Section 7, REPLACEMENT.

6.3. Measuring Die Opening

The die assembly will perform correctly as long as:

(1) the product specified is correct for the application,

(2) the specific die assembly is used, (3) the die

assembly has been measured to ensure that the

openings are correct, and (4) the die assembly

bottoms.

Figure 5 provides information on die opening sizes.

6.4. Ratchet Adjustment

(Figure 6)

The tool frame assembly ratchet mechanism features

an adjustment wheel with numbered settings. If the

crimp height is not acceptable, 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 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 crimp height is acceptable, secure the

lockscrew. If the dimension is unacceptable,

remove lockscrew and continue to adjust the

ratchet, and again measure a sample crimp.

408-4251

PRO-CRIMPER III Hand Too Assemb y 58573-1

Rev

of 4

Figure 6

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew

(Typ)

7. REPLACEMENT

Order replacements 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

P.O. BOX 3608

HARRISBURG, PA 17105–3608

8. REVISION SUMMARY

Since the previous release of this document, the

following changes have been made:

Per EC 0990–0465–05:

Updated document to corporate requirements

Added die set 58573–2 to title, Introduction,

and table in Figure 5

Changed lockscrew in Figures 1, 2, and 6

Changed PRO–CRIMPER II to

PRO–CRIMPER III in all instances

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