Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO-CRIMPER* III Hand Crimping

ool Assembly 58508-1 with 408-4372

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 N 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

16 JUN 09 Rev B

Die Assembly 58509-1

PROPER USE GUIDELINES

CumulativeTrauma Disorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume

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

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.

Moving Handle

Stationary Handle

Stationary Jaw

Back of Tool

(Wire Side)

Pivot Pin

PR -CRIMPER III Hand

Crimping Tool Frame

354940-1 ( 408-9930)

Ratchet Adjustment Wheel

Moving Jaw

Die Assembly

Front of Tool

Wire

E Die Assembly Product Family

}

Size

(AWG)

Strip Length (mm [in.])

(AWG) erminal Butt Splice

58509 1

Bud

et Terminal and 22-14 4.37-5.16

[.172-.203] 6.35-7.14

58509

Butt Splice 12-10 6.35-7.14

[.250-.281]

}

Contact the Tooling Assistance Center or the Product Information Center at the numbers listed below for specific terminal and butt splice

part numbers.

Figure 1

1. IN RODUC ION

PRO–CRIMPER III Hand Crimping Tool Assembly

58508–1 consists of Die Assembly 58509–1 and

PRO–CRIMPER III Hand Crimping Tool Frame

354940–1. The tool is used to crimp the terminals and

butt splices onto wire sizes listed in Figure 1.

Read these instructions thoroughly before crimping

any terminals or butt splices.

Reasons for reissue are provided in Section 10,

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.

2. DESCRIP ION

(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 three

crimping sections.

NO E

408-4372

PRO-CRIMPER III Hand Crimping Tool Assem ly 58508-1

Rev

of 5 Tyco Elect onics Co po ation

Figure 2

Tool F ame

Die Retaining

Sc ews

Wi e C impe

Wi e Anvil

22-16" Ma king on

C imping Section

The die assembly features a wire anvil and a wire

crimper. Die retaining screws are used to secure the

dies in the tool frame.

3. INSTALLATION AND REMOVAL OF DIE SET

(Figu e 2)

1. Open the tool handles and remove the two die

retaining screws from the tool jaws.

2. Place the wire anvil so that the crimping section

marked “22–16” faces outward when mounted in

the stationary jaw of the tool frame.

3. Insert the die retaining screw through the jaw

and through the anvil, and tighten the screw just

enough to hold the anvil in place. Do

not

tighten

the screw completely at this time.

4. Place the wire crimper so that the crimping

section marked “22–16” faces outward when

mounted in the moving jaw of the tool frame.

5. Insert the die retaining screw through the jaw

and through the crimper, and tighten the screw just

enough to hold the crimper in place. Do

not

tighten

the screw completely at this time.

6. Carefully close the tool handles, making sure

that the anvil and crimper align properly. Continue

closing the tool handles until the ratchet in the tool

frame has engaged sufficiently to hold the anvil

and crimper in place, then tighten both die retaining

screws.

7. To disassemble, close the tool handles until the

ratchet releases, remove the two die retaining

screws and slide the anvil and crimper out of the

tool jaws.

4. CRIMPING PROCEDURE

This tool is provided with a crimp ad ustment

feature. Initially, the crimp height should be

verified as specified in Figure 6. Refer to

Section 6, CRIMP HEIGHT INSPECTION, and

Section 7, RATCHET ADJUSTMENT, to verify

crimp height before using the tool to crimp

desired terminals or butt splices.

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

specified size. Strip the wire to the length indicated in

Figure 1, taking care not to nick or cut wire strands.

Select an applicable terminal or butt splice and

identify the appropriate crimping section according to

the wire size markings on the dies. Proceed as

follows:

1. Squeeze tool handles together until the ratchet

releases and then allow the tool jaws to open fully.

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

facing you. See Figure 3.

3. Holding the wire barrel, insert the terminal or

butt splice into the appropriate crimping section so

that the wire barrel seam faces the wire crimper

and the edge of the wire barrel is even with the

edge of the wire crimper.

NOTE

408-4372

PRO-CRIMPER III Hand Crimpin Tool Assembly 58508-1

of 5Rev

Tyco Elec ronics Corpora ion

Back of Tool

(Wire Side)

Wire

Figure 3

4. Hold the terminal or butt splice in position and

squeeze the tool handles together until ratchet

engages sufficiently to hold the terminal or butt

splice in position. Do NOT deform the wire barrel.

5. Insert stripped wire into the wire barrel of the

terminal or butt splice as follows:

a. For terminals, make sure that the end of the

wire is even with the edge of the wire barrel and

wire crimper, as shown in Figure 4, Detail A.

b. For butt splices, make sure that the end of

the wire butts against the internal wire stop of

the splice, as shown in Figure 4, Detail B.

6. Holding the wire in place, squeeze tool handles

together until ratchet releases. Allow tool handles

to open and remove crimped terminal or butt

splice.

The crimped terminal or butt splice may stick in

the crimping area; however, it can be easily

removed by pushing upward on the mating end of

the terminal or butt splice.

7. Inspect the crimped terminal or butt splice as

described in Section 5. Check the terminal or butt

splice crimp height as described in Section 6. If

necessary, adjust the crimp height as described in

Section 7, RATCHET ADJUSTMENT.

5. CRIMP INSPECTION

Inspect crimped terminals and butt splices by

comparing to the ones shown in Figure 5. Use only

the terminals and butt splices that meet the conditions

shown in the “ACCEPT” column. “REJECT” terminals

and butt splices can be avoided by carefully following

the above procedures and by performing regular tool

maintenance, as provided in Section 8,

MAINTENANCE AND INSPECTION.

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 manufacture or market

crimp–height comparators. Detailed information on

obtaining and using crimp–height comparators can be

found in instruction sheet 408–7424.

Figure 4

S rip Leng h

Edge of Wire Even

wi h Edge of Terminal

Wire Barrel and Edge

of Wire Anvil

Wire Crimper

NOTE:

No o Scale

S rip Leng h

Edge of Wire Bu s

Agains In ernal Wire

S op of Bu Splice

Wire Crimper

Detail A Detail B

NOTE

408-4372

PRO-CRIMPER III Hand Crim ing Tool Assembly 58508-1

Rev

of 5 Tyco Electronics Corporation

ACCEPT REJECT

Wire Range

Stamped Under

Tongue

Wire Range

Stamped Under

Tongue

1Full length of terminal wire barrel is crimped. 1Full length of terminal wire barrel was not crimped (wire

barrel was not even with edge of die).

2Wire size is within range stamped on terminal or tongue or

butt splice. 2Wire size is not within wire range stamped on terminal

tongue or butt splice.

3Wire fully inserted and acket does not enter wire barrel. 3Wire acket entered wire barrel of terminal or butt splice.

4Wire is flush with or extends slightly beyond end of terminal

wire barrel. 4End of conductor is not flush with or extending beyond end

of terminal wire barrel (wire not fully inserted).

5Splices crimped by full width of dies. 5Full length of butt splice was not crimped (wire barrel was

not even with edge of die).

6Wire range stamped on die matches wire range stamped on

terminal or butt splice. 6Narrow and extruded wire barrel indicates die closure too

small for terminal or butt splice and wire being used.

Compare wire ranges stamped on die and on terminal or

butt splice.

7Seam did not face wire crimper.

8Excessive flash indicates damaged dies.

9Nicked or missing conductor strands.

Figure 5

Proceed as follows:

1. Refer to Figure 6 and select a wire (maximum

size) for each crimping section listed.

2. Refer to Section 4, CRIMPING PROCEDURE,

and crimp the terminal(s) or butt splice(s)

accordingly.

3. Using a crimp height comparator, measure the

wire barrel crimp height as shown in Figure 6. 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 (Crimp Height) ADJUSTMENT.

408-4372

PRO-CRIMPER III Hand Crimping Tool Assembly 58508-1

of 5Rev

Tyco Electronics Corporation

Position Point

on Center of

Wire Barrel

Opposite

Seam

A"

Modified Anvil

WIRE SIZE CRIMPING SECTION CRIMP HEIGHT

(AWG) (Max) (Wire Size Marking) DIMENSION A

16 22-16 1.85+0.05

[.073+.002

14 16-14 2.11+0.05

[.083+.002

10 12-10 3.71+0.05/-0.08

[.146+.002/-.003

Figure 6

7. RATCHET (Crimp Height) ADJ STMENT

(Figure 7)

1. Remove the lockscrew from the ratchet

adjustment wheel.

2. With a screwdriver, adjust the ratchet wheel

from the front 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. Re–assemble the lockscrew.

Screwdriver

Ratchet

Adjustment

Wheel

Lockscrew

Figure 7

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 AND INSPECTION

8.1. 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.

8.2. 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 sections for flattened,

chipped, worn, or broken areas. If damage or

abnormal wear is evident, the tool must be replaced.

See Section 9, REPLACEMENT.

9. 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 717–986–7605, or write to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS

PO BOX 3608

HARRISBURG, PA 17105–3608

10. REVISION S MMARY

Revisions to this instruction sheet include:

PRO–CRIMPER II Hand Tool became the

PRO–CRIMPER III Hand Tool

TE logo was applied

Format was updated to the current corporate

requirements

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