1658541-1 - Tyco Electronics

Instruction Sheet

PRO- CRIMPER III Hand Crimping

Tool Assembly 58448- 2 408--9357

LOC B

1of 5

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

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

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

24 AUG 09 Rev DWith Die Assembly 58448- 3

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.

Stationary Jaw

Pivot Pin

PRO--CRIMPER III Hand Crimping

Tool Frame 354940-- 1 (408--9930)

Back of Tool

(Wire Side)

Stationary Handle

Movable Handle

Locator

Assembly

Front of Tool

(Locator Side)

Die Assembly

Moving Jaw

Ratchet Adjustment

Wheel

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 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.

Wire

TE Die

Assembly

Locator

Assembly{Product Family}Size Range

(AWG)

Insulation Diameter (Max)

(mm [in.])

Strip Length

(mm [in.])

AMPLIMITE*

HDP--20 Connector 28--24 1.02 [.040]

[

]

58448--3 1214310--1

Crimp Snap--In Contacts

with Insulation Support 24--20 1.52 [.060]

2.54 [.100

]

{Supplied with die assembly. Also available separately.

}Contact the Tooling Assistance Center or Product Information at the numbers listed below for specific contact part numbers.

Figure 1

1. INTRODUCTION

PRO--CRIMPER III Hand Crimping Tool Assembly

58448--2 consists of Die Assembly 58448--3 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.

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Figures are not drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 10, REVISION SUMMARY.

2. DESCRIPTION

The tool features a tool frame with a stationary jaw

and handle, moving jaw, moving handle, and

adjustable ratchet that ensures full contact crimping.

The tool frame holds a die assembly with two

crimping chambers. See Figure 1.

The die assembly features a wire anvil, insulation

anvil, wire crimper, and insulation crimper.

Die retaining pins and die retaining screws are used

to position and secure the dies in the tool frame.

Attached to the outside of the frame is a locator

assembly, which contains a locator and contact

retainer. A nut is used on the upper die retaining

screw to hold the locator assembly in place.

NOTE

408- 9357

PRO- CRIMPER III Hand Crimping Tool Assembly 58448- 2

Rev D2 of 5 Tyco Electronics Corporation

Locator

Assembly

Figure 2

Short Die Retaining

Screw

Long Die Retaining

Screw

Short Die

Retaining Pins

Long Die Retaining Pins

(Supplied with Locator Assembly)

Tool Frame

Nut

Locator

Chamfered

Edge

Wire Crimper

Offset

Wire Anvil

Insulation

Anvil

Insulation

Crimper

Chamfered

Edge

3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY

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

the chamfered sides and marked surfaces face

outward, when mounted in the moving jaw of the

tool frame.

3. Insert the two short die retaining pins through

the tool frame and into the anvils.

4. Insert the short 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 long die retaining pins (supplied

with the locator assembly) through the tool frame

and into the crimpers.

7. Insert the long 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. Remove the pin from the center hole in the

locator assembly. Place the locator assembly over

the end of the long die retaining screw and long die

retaining pins. 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. 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. CRIMPING PROCEDURE

This tool is provided with a crimp adjustment

feature. Initially, the crimp height should be

verified as specified in Section 5, CRIMP

HEIGHT INSPECTION, and Section 6,

RATCHET (Crimp Height) ADJUSTMENT, before

using the tool to crimp desired contacts.

Refer to Figure 1, and select wire of the specified size

and insulation diameter. Strip the wire to the length

indicated, taking care not to nick or cut wire strands.

Select an applicable contact and identify the

appropriate crimping chamber according to the wire

size markings on the tool.

Refer to Figure 3, and proceed as follows:

NOTE

408- 9357

PRO- CRIMPER III Hand Crimping Tool Assembly 58448- 2

3of 5Rev DTyco Electronics Corporation

1. Hold the tool so that the front (locator side) is

facing you. Squeeze tool handles together and

allow them to open fully.

2. Insert the contact—mating end first—into the

hole in the locator which corresponds with the

appropriate crimping chamber. Make sure that the

open “U” of the wire barrel and insulation barrel

face the stationary jaw.

Do NOT attempt to close the tool handles when

locator contact retainer is between the dies.

Damage to the tool jaws or locator may result.

3. Slide the locator contact retainer out from

between the dies (spring tension will pull the

locator down). Make sure that the wire stop enters

the contact wire stop slot between the wire barrel

and contact shoulder. Release contact retainer.

Make sure that both sides of the contact

insulation barrel are started evenly into the

crimping chamber. 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 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 can be removed by pushing downward

on the top of the locator (see Figure 3).

7. Check the contact 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

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 the maximum size

wire for the crimping chamber.

2. Refer to Section 3, CRIMPING PROCEDURE,

and crimp the contact 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, the tool is

considered dimensionally correct. If not, the tool

must be adjusted. Refer to Section 6, CRIMP

HEIGHT ADJUSTMENT.

Figure 3

Wire Strip Length

Locator in

Contact Wire

Stop Slot

Wire Inserted to

Locator Wire Stop

Tool Stationary

Jaw

Wire

Tool Wire

Size Markings

Back of Tool

(Wire Side)

Contact

Retainer

Locator

CAUTION

NOTE

408- 9357

PRO- CRIMPER III Hand Crimping Tool Assembly 58448- 2

Rev D4 of 5 Tyco Electronics Corporation

Position Point

on Center of

Wire Barrel

Opposite

Seam Spindle

Modified

Anvil

Crimp

Height

Wire Size (AWG)

(Max)

Crimp Height Dimension

+0.05 mm [+.002 in.]

24 0.724 [.0285]

20 0.749 [.0295]

Figure 4

6. RATCHET (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.

4. Re--assemble the lockscrew.

5. Make a sample crimp and measure the crimp

height.

6. If the dimension is unacceptable, continue to

adjust the ratchet, and again measure a sample

crimp.

Screwdriver

Ratchet Adjustment

Wheel

Lockscrew

(Typ)

7. 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. 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 chambers 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 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 SUMMARY

Revisions to this instruction sheet include:

SChanged PRO--CRIMPER II Hand Tool to

PRO--CRIMPER III Hand Tool;

SModified Crimp Height Inspection information;

SAdded the TE logo; and

SAdded alternate tools on back page.

408- 9357

PRO- CRIMPER III Hand Crimping Tool Assembly 58448- 2

5of 5Rev DTyco Electronics Corporation

PRO- CRIMPER III Hand Tool 354940-1

(Instruction Sheet 408- 9930)

SDE PEW-12 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)

Die Assembly 58448- 3 Can Be Used In the Following Tools: