PRO-CRIMPER* III Hand Crmpng Tool Assembly 58546-1 and De Assembles 58545-[ ] Instructon Sheet 408-8678 13 MAR 14 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended-use, producton operatons s avalable. PRO-CRIMPER III Hand Crmpng Tool 58546-1 Shown Front of Tool De Assembly 58545-1 Movng Jaw Statonary Jaw Pvot Pn Back of Tool (Wre Sde) PRO-CRIMPER III Hand Crmpng Tool Frame 354940-1 (Instructon Sheet 408-9930) ORIGINAL INSTRUCTIONS Ratchet Adjustment Wheel The PRO-CRIMPER III Hand Crmpng Tool s a Commercal grade tool and s desgned prmarly for feld nstallaton, repar, mantenance work, or prototypng n ndustral, commercal, or nsttutonal applcatons. Product crmped wth ths tool wll meet the crmp heght requrement for hand tools n the approprate Applcaton Specfcaton (114-seres), but may not comply wth other feature parameters of the specfcaton. TE Connectvty offers a varety of tools to satsfy your performance requrements. For addtonal nformaton, contact the Toolng Assstance Center at 1-800-722-1111. Movng Handle Statonary Handle DIE ASSEMBLY 58545-1 58545-3 58545-4 PRODUCT FAMILY (SOLISTRAND*) SIZE (AWG) WIRE STRIP LENGTH (mm [n.]) Termnal (Standard) 22-14 4.37-5.16 [.172-.203] Termnal (Standard) and Butt Splce 12-10 6.35-7.14 [.250-.281] Termnal (Long Barrel) or Butt Splce 22-14 6.35-7.14 [.250-.281] Termnal Parallel Splce 22-14 7.94-8.73 [.312-.344] Contact the Toolng Assstance Center or Product Informaton (at the number lsted below) for specfc termnal and splce part numbers. See page 6 for de assembly cross reference. Fgure 1 1. INTRODUCTION De Assembly 58545-[ ] and PRO-CRIMPER III Hand Tool 58546-1 are used to crmp SOLISTRAND Termnals and Splces onto the wre sze lsted n Fgure 1. PRO-CRIMPER III Hand Tool Assembly conssts of Hand Tool Frame 354940-1 and De Assembly 58545-1. Read these nstructons thoroughly before usng the tool assembly. Specfc part numbers for de set 58545-[ ] may be used wth other optonal crmp toolng. Refer to Fgure 7 for specfc relatonshps. Dmensons n ths nstructon sheet are n metrc unts [wth U.S. customary unts n brackets]. Fgures and llustratons are for reference only and are not drawn to scale. 2014 TE Connectvty famly of companes All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 6 LOC B
Statonary Jaw Indenters Upper De De Retanng Screws Lower De Anvls Fgure 2 Ths document supersedes Instructon Sheet 408-4047. Reasons for ressue of ths nstructon sheet are provded n Secton 8, REVISION SUMMARY. 2. DESCRIPTION (See Fgures 1 and 2) The tool consst of a statonary jaw and handle, a movng jaw and handle, and an adjustable ratchet that ensures full crmpng. The tool frame holds a de assembly wth three crmpng chambers. The de assembly features an upper de and a lower de. De retanng screws are used to poston and secure the des n the tool frame. 3. DIE ASSEMBLY INSTALLATION AND REMOVAL 1. Open the tool handles and remove the two de retanng screws from the tool jaws. 2. Place the upper de n the statonary jaw of the tool frame so that the largest ndenter s facng nward. See Fgure 2. 3. Insert the de retanng screw through the statonary jaw and through the de. Tghten the screw just enough to hold the de n place. Do not tghten the screw completely at ths tme. 4. Place the lower de n the movng jaw of the tool frame so that the largest anvl s facng nward. See Fgure 2. 5. Insert the de retanng screw through the movng jaw and through the de. Tghten the screw just enough to hold the de n place. Do not tghten the screw completely at ths tme. 6. Carefully close the tool handles, makng sure that the anvls and ndenters algn properly. Contnue closng the tool handles untl the ratchet has engaged suffcently to hold the des n place, then tghten both de retanng screws. 7. To dsassemble, open the tool handles untl the ratchet releases, remove the two de retanng screws, and slde the des out of the tool jaws. 4. CRIMPING PROCEDURE Before usng the tool, the crmpng chambers and tool ratchet should be nspected as specfed n Secton 5, CRIMP HEIGHT INSPECTION, and Secton 6, RATCHET (Shut Heght) ADJUSTMENT. Refer to Fgure 1 and select wre of the specfed sze and nsulaton dameter. Strp the wre to the length ndcated, takng care not to nck or cut wre strands. Select an applcable termnal or splce and dentfy the approprate crmpng chamber accordng to the wre sze markngs on the des. Refer to Fgure 3 and proceed as follows: The crmpng chamber marked 12-10 cannot be used to crmp spade-type termnals. 1. Hold tool so that the back (wre sde) s facng you. Squeeze tool handles together untl the ratchet releases, then allow them to open fully. 2. Center the termnal or splce wre barrel on the anvl of the upper de as shown n Fgure 3. If vsble, be sure to place the brazed seam on the termnal or splce toward the ndenter. 2 of 6
Termnal Termnal Wre Barrel Centered on Anvl of Lower De Splce Strpped Wre hold the termnal or splce n poston. Do NOT deform the nsulaton barrel or wre barrel. 4. Insert strpped wre nto the wre barrel, makng sure that the nsulaton does not enter the wre barrel. See Fgure 3. 5. To crmp the other half of a splce, reposton the uncrmped wre barrel n the crmpng chamber, and repeat the crmpng procedure. 6. To crmp the other half of a splce, reposton the uncrmped wre barrel n the crmpng chamber, and repeat the crmpng procedure. If splce cannot be turned for crmpng the other half, turn the tool around. 7. Inspect the crmped termnal or splce accordng to Fgure 4. Check the crmp heght as descrbed n Secton 5. If necessary, adjust the ratchet (shut heght) as descrbed n Secton 6. Termnal Splce Wre Barrel Centered on Anvl of Lower De Parallel Splce Butt Splce Brazed Seam Postoned Toward Indenter Inspecton Hole Parallel Splce Splce Wre Barrel Centered on Anvl of Lower De Fgure 3 3. Hold the wre barrel n place and squeeze the tool handles together untl ratchet engages suffcently to Fgure 4 3 of 6
CAUTION! Damaged termnals and splces may not be used. If a damaged termnal or splce s evdent, t must be replaced wth a new one. 5. CRIMP HEIGHT INSPECTION Ths nspecton requres the use of plug gages conformng to the dmensons provded n Fgure 5. TE does not manufacture or market these gages. To gage the crmpng chamber, proceed as follows: 1. Remove traces of ol or drt from the crmpng chamber and plug gage. 2. Close the tool handles untl the des have bottomed. Do NOT force des beyond ntal contact. for 58545-[ ] 3. Algn the GO element wth the crmpng chamber. Push element straght nto the crmpng chamber wthout usng force. The GO element must pass completely through the crmpng chamber. See Fgure 5. 4. Algn the NO-GO element and try to nsert t straght nto the same crmpng chamber. The NO-GO element may start entry, but must not pass completely through the crmpng chamber. See Fgure 5. If the crmpng chamber conforms to the gage nspecton, the tool s consdered dmensonally correct, and should be lubrcated wth a THIN coat of any good SAE 20 motor ol. If not, the tool must be returned to TE for further evaluaton and repar. Refer to Secton 8, REPLACEMENT. For addtonal nformaton regardng the use of a plug gage, refer to Instructon Sheet 408-7424. CRIMPING CHAMBER (De Markng) 22-16 16-14 12-10 GAGE ELEMENT DIMENSIONS GO NO-GO R (RADIUS) 1.143-1.151 [.0450-.0453] 1.346-1.354 [.0530-.0533] 1.905-1.913 [.0750-.0753] 1.344-1.346 [.0529-.0530] 1.547-1.549 [.0609-.0610] 2.106-1.108 [.0829-.0830] 1.57 [.062] 1.98 [.078] 2.77 [.109] 6. RATCHET (SHUT HEIGHT) ADJUSTMENT (Fgure 6) The frame assembly ratchet mechansm features an adjustment wheel wth numbered settngs. If the des do not bottom, adjust the ratchet as follows: 1. Remove the lockscrew from the ratchet adjustment wheel. 2. Wth a screwdrver, adjust the ratchet wheel from the opposte sde of the frame. 3. Observe the ratchet adjustment wheel. If the des do not bottom, rotate the adjustment wheel COUNTERCLOCKWISE to a hgher-numbered settng. 4. Replace the lockscrew. Screwdrver GO Element Must Pass Completely Through Crmpng Chamber NO-GO Element May Start Entry, But Must Not Pass Completely Through Crmpng Chamber Fgure 5 Ratchet Adjustment Wheel Lockscrew Fgure 6 4 of 6
7. MAINTENANCE AND INSPECTION 7.1. Mantenance Ensure that the tool and des are clean by wpng them wth a clean, soft cloth. Remove any debrs wth a clean, soft brush. Do not use objects that could damage the tool. When not n use, keep handles closed to prevent objects from becomng lodged n the crmpng des, and store n a clean, dry area. 7.2. Vsual Inspecton The de assembly should be nspected on a regular bass to ensure that they have not become worn or damaged. Inspect the crmpng chambers for flattened, chpped, worn, or broken areas. If damage or abnormal wear s evdent, the tool or des must be replaced. See Secton 8, REPLACEMENT. 8. REPLACEMENT Customer-replaceable parts are shown n Fgure 1. Avalable separately, PRO-CRIMPER III Hand Crmpng Tool Repar Kt 679221-1 ncludes a replacement nut and a varety of pns, rngs, screws, and sprngs. If the des are damaged or worn excessvely, they must be replaced. Order the repar kt and replaceable parts through your TE Representatve, or call 1-800-526-5142, or send a facsmle of your purchase order to 717-986-7605, or wrte to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 For tool repar servce, please contact a TE Representatve at 1-800-526-5136. 9. REVISION SUMMARY Updated document to corporate requrements Added clarfyng note to table n Fgure 1 5 of 6
Toolng Compatble wth De Assembly 58545-[ ] De Assembly 58545-1 for PRO-CRIMPER III Hand Tool Frame 354940-1 (Instructon Sheet 408-9930) De Assembly 58545-1 for SDE-SA Hand Tool 9-1478240-0 (Instructon Sheet 408-8851) De Assembly 58545-3 for SDE Bench Termnator 1490076-2 (Customer Manual 409-10052) De Assembly 58545-4 for 626 Adapter 679304-1 (Instructon Sheet 408-4070) De Assembly 58545-3 for Electro-Hydraulc (BT 3500 Battery-Hydraulc) Hand Tool Kts 2031400-[ ] (Customer Manual 409-10095) Closed Head Assembly 2031460-1 (Instructon Sheet 408-10312) C -Head Assembly 2031450-1 (Instructon Sheet 408-10311) Fgure 7 6 of 6