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Instruction SheetPRO- CRIMPER* III Hand Crimping Tool Assembly 58535- 1 with 408- -4021 LOC B 1 of 6E2009 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 atwww.tycoelectronics.com
29 JUL 09 Rev CDie Assembly 58535- 2
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. Moving Jaw Stationary Jaw PRO- -CRIMPER III Hand Crimping Tool Frame 345940- -1 (408- -9930) Pivot Pin Stationary Handle Moving Handle Ratchet Adjustment Wheel Front of Tool (Lower Side) Die Assembly Locator Assembly (Supplied with Die Assembly) The PRO- -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 Technical Assistance Center at 1 - -800 - -722 - -1111. Back of Tool (Wire Side) { Contact Wire TE Die Assembly Locator Assembly{ Contact Family} Size (AWG) Ins. Dia. (mm [In.]) Strip Length (mm [In.]) 58535- -2 58516- -1 FFC Round Wire Pin and Receptacle Contacts 26- -22 1 . 0t o1 . 4 [.040 to .056] 2 . 8t o3 . 6 .110 to .140 } Supplied with Die Assembly.. Also Available separately. } Contact the T echnical Assistance Center or Product Information (see below) for specific contact part numbers. Figure 1 1. INTRODUCTION PRO- -CRIMPER III Hand Crimping Tool Assembly 58535- -1 consists of Die Assembly 58535- -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. Dimensions on this sheet are inmillimeters [with inch equivalents provided in brackets]. Figures and illustrations are for identification only and are not drawn to scale. Reasons for reissue are provided in Section 11, REVISION SUMMARY. 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 NOTE i
408- 4021PRO- CRIMPER III Hand Crimping Tool Assembly 58535- 1 Rev C2 of 6 Tyco Electronics Corporation 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, which contains a locator, a spring retainer, and a contact support. 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 upper 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 short die retaining screw through the jaw and through both anvil dies, and tighten the screw just enough to hold the dies in place. Donot 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 long die retaining screw through the jaw and through both crimper dies, and tighten the screw just enough to hold the dies in place. Donot 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. 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. Figure 2 Locator Chamfer Wire Crimper Nut Offset Wire Anvil Insulation Anvil Insulation Crimper Chamfer Locator Assembly Tool Frame Die Retaining Pins Die Retaing Screws
408- 4021PRO- CRIMPER III Hand Crimping Tool Assembly 58535- 1 5 of 6Rev C Tyco Electronics Corporation 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 CORPORATION PO BOX 3608 HARRISBURG PA 17105- -3608 11.REVISION SUMMARY Revisions to this instruction sheet include: S Revision to figure 3 to illustrate the contact stabilizer; and S Addition of back page, indicating tooling that will handle die 58535- -2.
408- 4021PRO- CRIMPER III Hand Crimping Tool Assembly 58535- 1 Rev C6 of 6 Tyco 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 58535- 2 Can Be Used In the Following Tools: