Tyco Electronics PRO-CRIMPER III Bedienungsanleitung

Instruction Sheet

PRO-CRIMPER* III Hand Crimping

Tool Assembly 58541-1 408-4051

L C B

of 4

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

28 APR 09 Rev B

with Die Assembly 58541-2

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromtheprolongeduseof manuallypoweredhandtools.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 application 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 Technical Assistance Center at

1-800-722-1111.

Front of Tool

(Locator Side)

Ratchet

Adjustment

Wheel

Back of Tool

(Wire Side)

Pivot Pin

Moving Jaw

Moving Handle

Stationary

Handle

Die

Assembly

Stationary Jaw

PR -CRIMPER III Hand

Crimping

Tool Frame 35494-1 (See

instruction sheet 408-9930)

Die Assembly

Locator Assembly

Contact

Wire

Die Assembly

Part Number

Locator Assembly

Part Number

{

Contact

Family

}

Size

(AWG) Insulation Diameter

(mm [In. ) Strip Length

(mm [In. )

58541-2

189382-1

67 MULTIMATE*

Type II Series

24-22 1.40 to 2.16

[.055 to .085] 5.32

[.209]

58541

189382

Type II Series

Contacts 18-14 PEN 6.35

[.250]

{

Supplied with the die assembly. Also available separately.

}

Contact the Product Information Center (below) for specific contact part numbers.

Figure 1

1. INTRODUCTION

PRO–CRIMPER III Hand Crimping Tool

Assembly 58541–1 consists of Die Assembly

58541–2 and PRO–CRIMPER III Hand Crimping Tool

Frame 354940–1. The die assembly consists of

crimping dies and a locator assembly. Refer to

Figure 1.

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.

NOTE

408-4051

PRO-CRIMPER III Hand Crimping Tool Ass mbly 58541-1

Rev

of 4 Tyco Electro ics Corporatio

Figure 2

Nut Locator

Assembly

Wire Crimper

Wire A vil

I sulatio

Crimper

I sulatio

A vil

Die Retai i g

Pi s

Die Retai i g

Screws

Tool Frame

Chamfer

Offset

Locator

Reasons for reissue are provided in Section 10,

REVISION SUMMARY.

2. DESCRIPTION

(Figure 1 a d 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.

The tool frame holds a die assembly with two

crimping sections.

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.

Die retaining pins and die retaining screws are used

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

nut is used on the lower die retaining screw to hold

the locator assembly 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 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 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 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.

11. 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.

408-4051

PRO-CRIMPER III Hand Crimping Too Assemb y 58541-1

of 4Re

Tyco Electronics Corporation

Figure 3

Wire

Inserted

in Contact

Strip

Length

Contact (Typ)

Back of Tool

(Wire Side)

Wire

Locator

Contact

Shoulder

Against

Locator

4. CRIMPING PROCEDURE

This tool is provided with a crimp adjustment

feature. Initially, the crimp height should e

verified as specified in Figure 4. Refer to

Section 5, CRIMP HEIGHT INSPECTION, and

Section 6, CRIMP HEIGHT ADJUSTMENT, to

verify crimp height efore 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 crimp section according

to the wire size markings on the tool. 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 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. Refer

to Figure 3. Butt the contact shoulder against the

locator.

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. Fully insert the stripped wire into the contact as

shown in Figure 3.

6. While holding the wire in place, squeeze the tool

handles together until ratchet releases. Allow the

tool handles to open, and remove the crimped

contact.

7. Check the contact’s crimp height as described in

Section 5, CRIMP HEIGHT INSPECTION. If

necessary, adjust the crimp height as described in

Section 6, CRIMP HEIGHT ADJUSTMENT.

5. CRIMP HEIGHT INSPECTION

This inspection requires the use of a micrometer with

a modified anvil.

Tyco Electronics does not manufacture or market

these gages. Hovever, TE recommends the

modified micrometer (Crimp Height Comparator

RS-1019-5LP) .

Proceed as follows:

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

size) for each crimp section listed.

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

NOTE

CAUTION

NOTE

408-4051

PRO-CRIMPER III Hand Crimping ool Assembly 58541-1

Rev

of 4 Ty o Ele troni s Corporation

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 6,

CRIMP HEIGHT ADJUSTMENT.

Figure 4

WIRE SIZE

AWG (MAX) CRIMP SEC ION

(WIRE SIZE MARKING)

CRIMP HEIGH

DIM. (A) AND

OLERANCE (+)

Position

Point on

Center of

Wire Barrel

Opposite the

Seam

Modified

Anvil

A"

20-24

18-16-14

1.09

.051

[.043

.002]

160

.051

[.063

.002]

6. CRIMP HEIGH ADJUS MEN

(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.

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.

7. MAIN ENANCE

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.

Figure 5

S rewdriver

Rat het

Adjustment

Wheel

Lo ks rew

(Typ)

8. VISUAL INSPEC ION

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 9, REPLACEMENT.

9. REPLACEMEN

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

10. REVISION SUMMARY

Since the previous release of this document:

The TE logo was applied;

The PROCRIMPER II Hand Tool became the

PRO–CRIMPER III Hand Tool; and

The format of the sheet was updated to the

current corporate requirements.

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