Tyco Electronics PRO-CRIMPER III User manual

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Instruction Sheet

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

1of 6

LOC B

PRO-CRIMPER* III Hand

Crimping Tool Assembly And

Die Set 58517-[ ] 408-4064

07 DEC 10 Rev D

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.

Figure 1

1. INTRODUCTION

PRO-CRIMPER III Hand Crimping Tool Assembly

58517-1 consists of Die Assembly 58517-2 and

PRO-CRIMPER III Hand Tool Frame 354940-1. See

Figure 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 are provided in Section 11,

REVISION SUMMARY.

2. DESCRIPTION )

See Figure 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.

PRO-CRIMPER

III HAND TOOL

DIE ASSEMBLY

PART NUMBER

LOCATOR

PART

NUMBER‡

CONTACT

FAMILY

WIRE

SIZE

(AWG)

INSUL DIA

(mm [In.])

STRIP LENGTH

(mm [In.])

58517-1 58517-2 189590-1 CST 100

26-22 0.89-1.65

[.035-.065]

2.54-2.92

[.100-.125]

58517-3 58517-4 1424907-1 CST 100 II

None 58517-5 • 1901843-1 CST 100 II

• Bench Machine/Battery Tool Only ‡ Supplied with thedie assembly. Also available

separately.

‡‡ Contact the PRODUCT INFORMATION CENTER for specific contact part

numbers.

NOTE

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 Application Specification (114-series), 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.

Locator

(Supplied with

Die Assembly)

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

(Instruction

Sheet 408-9930)

Moving

Jaw

Handle

408-4064

2of 6

Rev D

Figure 2

The tool frame holds a die assembly with one crimping

section.

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, which

holds and helps to position the contact.

Die retaining pins and die retaining screws are used to

position and secure the dies in the tool frame. A

washer and nut is used on the lower die retaining

screw to hold the locator in place.

3. INSTALLATION AND REMOVAL OF 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 wire anvil and insulation anvil in the

moving jaw 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 long 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

in the stationary jaw 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 short 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 over the end of the long

screw, and position the locator against the side of

the tool jaw.

10. Place the washer and nut onto the end of the

long screw. Align the locator slot with the

crimping section and carefully tighten the nut.

11. To disassemble, close the tool handles until

the ratchet releases, remove the nut, the washer,

the locator, the two die retaining screws, and the

four die retaining pins, and slide the anvils and

crimpers out of the tool jaws.

Die Retaining

Pins

Nut

Washer

Wire Anvil Chamfer

Insulation

Anvil

Offset

Wire

Crimper

Chamfer

Insulation

Crimper

Die Retaining Screws

Locator

Tool Frame

((or Bench

Machine, or

Ratchet Hand

Tool)

Adjustment

Screw Nut

408-4064

3of 6

Rev D

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 6, Crimp

Height Inspection, and Section 7, 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 die assembly according to the

wire size markings on the die. 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 insulation barrel,

insert the contact—mating end first—into the

locator slot. Position the contact so that the open

“U” of the wire and insulation barrels face the top

of the tool. Make sure the contact butts against

the adjustment screw. Check that the contact is

centered with the die assembly wire and

insulation anvils. If adjustment is required, refer to

Section 5, CONTACT SUPPORT ADJUSTMENT.

Make sure that both sides of the insulation barrel

are started evenly into the crimping section. Do not

attempt to crimp an improperly positioned contact.

3. 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.

The ratchet has detents that create audible clicks

as the tool handles are closed.

4. Insert stripped wire into contact insulation and

wire barrels until it is butted against the wire stop

on the contact, as shown in Figure 3.

5. Holding the wire in place, squeeze tool handles

together until ratchet releases. Allow tool handles

to open and remove crimped contact.

6. 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, CRIMP HEIGHT ADJUSTMENT.

5. CONTACT SUPPORT ADJUSTMENT (Figure 3)

1. .Make a sample crimp according to Section 4,

CRIMPING PROCEDURE. If the crimp is out of

alignment, adjustment is required.

2. To move the contact from side-to-side, loosen

the nut that holds the locator to the frame and

slide the locator until the contact is properly

positioned. Hold the locator in place and tighten

the nut.

Figure 3

NOTE

TOOL DIMENSION A

58517-1, 58517-2, 2.641 [.104]

58517-3, 58517-4 4.191 [.165]

58517-5

Wire Inserted to

Contact Wire Stop

Locator Slot Wire

Back of Tool

(Wire Side) Adjustment

Screw

408-4064

4of 6

Rev D

3. To move the contact in or out, loosen the nut

on the adjustment screw and turn the screw until

the contact is properly positioned. Hold the screw

in place and tighten the nut.

4. If the crimp is still out of alignment, repeat the

adjustment procedure.CRIMP HEIGHT

INSPECTION. .

Figure 4

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 market crimp height

comparators. Refer to Instruction Sheet 408-7224

for detailed information on obtaining and using a

crimp height comparator.

Proceed as follows:

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

size) for the crimp section.

2. Refer to Section 4, 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 ADJUSTME

7. .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.

Figure 5

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.

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 section for flattened,

chipped, worn, or broken areas. If damage or

abnormal wear is evident, the tool must be replaced.

See Section 10, REPLACEMENT.

WIRE SIZE

AWG (Max)

CRIMP SECTION

(WIRE SIZE

MARKING)

CRIMP HEIGHT

DIM (A) AND

TOLERANCE (±)

22 26-22 0.79±0.05

[.031±.002]

Screwdriver

Ratchet

Adjustment

Pawl

Lockscrew

408-4064

5of 6

Rev D

10. REPLACEMENT

Customer-replaceable parts are shown in Figure 1.

Available separately, PRO-CRIMPER III Hand 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 (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

11. REVISION SUMMARY

Since the previous release of this sheet, the following

changes were made:

•Format was updated to current corporate

requirements; and

•Die Set was added for the battery tool and bench

machine.

408-4064

6of 6

Rev D

PRO-CRIMPER III Hand Tool Frame 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)

Use Die Sets

58517-2 or

58517-4

Use Die Sets

58517-2 or

58517-4

Use Die Set 58517-5 Use Die Set 58517-2 or 58517-4

Use Die Set 58517-5 Use Die Set 58517-5

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