Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO-CRIMPER* III Hand Crimping

Tool Assembly 58596-1 with 408-4348

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

04 JUN 09 Rev A

Die Assembly 58596-2

PROPER SE G IDELINES

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)

Pivot Pin

The PR -CRIMPER III Hand Crimping Tool Assembly 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.

PR -CRIMPER III Hand

Crimping Tool Frame

354940-1 (408-9930)

Stationary Handle

Moving Handle

Locator Assembly

(Supplied with

Die Assembly)

Front of Tool

(Locator Side)

Die Assembly

Guide Contact

Moving Jaw

Ratchet Adjustment Wheel

TE Die

TE Locator

Contact

Wire

TE Di

Assembly

TE L

oca

Assembly

{

Family

}

Size

(mm2)Insul Dia

(mm [in.]) Strip Length

(mm [in.])

58596-2 58515-5 Power

Quadlok

Seal 4.0 4.09

[.161] 4.83 - 5.59

[.190 - .220]

{

Supplied with die assembly, also available separately.

}

Contact the Tooling Assistance Center or Product

Information Center (see below) or specific contact part

numbers.

Figure 1

1. INTROD CTION

PRO–CRIMPER III Hand Crimping Tool Assembly

58596–1 consists of Die Assembly 58596–2 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.

Reasons for revision can be found in Section 11,

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

408-4348

PRO-CRIMPER III Hand Crimping Tool Assem ly 58596-1

Rev

of 5 Tyco Electronics Corporation

Figure 2

Nut Locator

Asse bly Tool Fra e

Die Retaining Pins

Die Retaining Screws

Cha fer

Insulation Anvil

Wire Anvil

Offset

Wire Cri per

Cha fer Insulation

Cri per

Guide Contact

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 contact crimping.

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

assembly, which contains a locator, a spring retainer,

and a contact support.

Attached to the outside of the movable jaw is a

contact guide. Die retaining pins and die retaining

screws are used to position and secure the dies in the

tool frame. Nuts are used on the upper die and

movable jaw retaining screws to hold the locator

assembly and contact guide 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 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 long die retaining pins.

4. Insert the 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 short die retaining pins.

7. Insert the 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. Place the contact guide over the retaining

screw and the two pins.

408-4348

PRO-CRIMPER III Hand Crimpin Tool Assembly 58596-1

of 5Rev

Tyco Electronics Cor oration

12. Secure the contact guide to the movable jaw

with a nut. Do not tighten the nut completely at this

time.

13. Place a contact in the anvil and adjust the

contact guide to fit the contact.

14. When contact guide is correctly positioned,

tighten the nut.

15. To disassemble, close the tool handles until the

ratchet releases, remove the nut, the locator

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

(Figure 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,

RATCHET 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. 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 crimp section according

to the wire size markings on the tool. Refer to

Figure 3 and proceed as follows:

Figure 3

Adjustment

Screw for

Contact

Su ort

Contact

Su ort Locator

Back of Tool

(Wire Side)

Wire

Contact

(Ty )

Locator in

Wire Sto Slot Wire

Inserted

to Sto

Stri

Length

Wire

Seal

Wire Seal

Contact

Guide

NOTE

408-4348

PRO-CRIMPER III Hand Crimping Tool Assembly 58596-1

Rev

of 5 Tyco Electronics Corporation

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 crimp section.

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

must 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.

Make sure that both sides of the insulation barrel

are started e enly into the crimping section. 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.

The crimped contact may stick in the crimping

area, but the contact can be easily remo ed by

pushing downward on the top of the locator (see

Figure 3).

7. 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, RATCHET ADJUSTMENT.

6. CRIMP HEIGHT IN PECTION

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.

Position Point

on Center of

Wire Barrel

Opposite

Seam

A"

Modified Anvil

WIRE IZE CRIMP ECTION CRIMP HEIGHT

DIM.

(

)

AND

mm2(MAX) (WIRE IZE MARKING)

()

TOLERANCE

+.05 [+.002]

4.0 4.0 2.34

[.092]

Figure 4

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.

7. RATCHET (Crimp Height) ADJU TMENT

(Fi ure 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.

Figure 5

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew

(Typ)

CAUTION

NOTE

408-4348

PRO-CRIMPER III Hand Crimpin Tool Assembly 58596-1

of 5Rev

Tyco Electronics Corporation

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.

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 sections 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

Revisions to this instruction sheet include:

PRO–CRIMPER II Hand Tool became the

PRO–CRIMPER III Hand Tool;

The TE logo was applied; and

the format was updated to the current

corporate requirements.

Dieses Handbuch passt für folgende Modelle

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