Instruction Sheet
PRO-CRIMPER* III Hand Crimping
408-4031
Tool Assembly 58548-1
with Die Assembly 58548-2
28 APR 09
Rev B
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.
Locator
Stationary Jaw
Assembly
(Supplied with
Back of Tool
Die Assembly)
(Wire Side)
Front of Tool
Pivot Pin
(Locator Side)
Die
PRO-CRIMPER III Hand Crimping
Assembly
Tool Frame 35494-1 (See
instruction sheet 408-9930)
Moving Jaw
Ratchet
Adjustment
Wheel
Stationary
Handle
Moving Handle
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 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.
Wire
Die Assembly
Locator Assembly
Part Number
58548-2
Part Number
Contact
{
Family
}
Insulation Diameter
Strip Length
(mm [In.])
(mm [In.])
1.1 to 1.7
26-22
56El and
58516-1
Size
(AWG)
[.043 to .067]
MTEl Series
20
{
Supplied with the die assembly. Also available separately.
}
Contact the Product Information Center (below) for specific contact part numbers.
PRO–CRIMPER III Hand Tool Assembly 58548–1
consists of Die Assembly 58548–2 and
PRO–CRIMPER III Hand Tool Frame 354940–1. The
die assembly consists of crimping dies and a locator
assembly.
Read these instructions thoroughly before crimping
2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
1.9 [ .075] max
Figure 1
any contacts.
1. INTRODUCTION
E
3.2 to 3.7
[ 126to .146]
[.126to
146]
NOTE
Dimensions on this sheet are in millimeters [with
inch equivalents provided in brackets]. Figures
i
and illustrations are for identification only and are
not drawn to scale.
Reasons for reissue are provided in Section 11,
REVISION SUMMARY.
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
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LOC B
408-4031
PRO-CRIMPER III Hand Crimping Tool Assembly 58548-1
Nut
Locator
Assembly
Tool Frame
Locator
Die Retaining
Insulation
Pins
Crimper
Chamfer
Wire Crimper
Offset
Wire Anvil
Insulation
Chamfer
Die Retaining
Anvil
Screws
Figure 2
2. DESCRIPTION
(Figure 1)
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, 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
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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 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. 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.
Tyco Electronics Corporation
Rev
B
408-4031
PRO-CRIMPER III Hand Crimping Tool Assembly 58548-1
Contact
Locator
Support
Back of Tool
Adjustment
(Wire Side)
Screw for
Contact
Support
Contact
Strip Length
(Typ)
Wire
Locator in
Wire Stop Slot
Wire Inserted
to Stop
Figure 3
4. CONTACT SUPPORT ADJUSTMENT (Figure 3)
NOTE
contact is still being bent during crimping, repeat
the adjustment procedure.
The contact support is preset prior to shipment,
but minor adjustment may be necessary.
5. CRIMPING PROCEDURE
i
1. Make a sample crimp and determine if the
contact is straight, bending upward, or bending
downward.
NOTE
feature. Initially, the crimp height should be
i
The ratchet has detents that create audible clicks
as the tool handles are closed.
i
3. Place a contact with wire into the proper nest
and close the tool handles until the ratchet reaches
the sixth click, or until the contact support touches
the contact.
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
5. Move the contact support as required to
eliminate the bending of the contact.
6. Tighten the nut and close the handles until the
ratchet releases.
7. Remove and inspect the contact.
8. Make another sample crimp. If the contact is
straight, tighten the contact support screw. If the
Rev
B
verified as specified in Figure 4. Refer to
Section 6, CRIMP HEIGHT INSPECTION, and
Section 7, CRIMP HEIGHT ADJUSTMENT, to
2. If adjustment is required, loosen the screw that
holds the contact support onto the locator
assembly.
NOTE
This tool is provided with a crimp adjustment
verify crimp height before 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, and so
that the open “U” of the wire and insulation barrels
face the top of the tool. Place the contact up into
the nest so that the movable locator drops into the
slot in the contact. Refer to Figure 3. Butt the front
end of the wire barrel against the movable locator.
Tyco Electronics Corporation
3 of 5
408-4031
PRO-CRIMPER III Hand Crimping Tool Assembly 58548-1
CAUTION
!
Make sure that both sides of the insulation barrel
Position
are started evenly into the crimping section. Do
Point on
NOT attempt to crimp an improperly positioned
Center of
contact.
Wire Barrel
Opposite
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.
NOTE
Seam
Modified
A"
Anvil
WIRE SIZE
CRIMP SECTION
AWG (MAX)
(WIRE SIZE MARKING)
22
26-22
20
20
pushing downward on the top of the locator (see
This inspection requires the use of a micrometer with
a modified anvil.
Tyco Electronics does not manufature or market
these gages. However, TE recommends the
(Crimp Height
Comparator RS–1019–5LP).
modified micrometer
.05
"
"
.05
.002]
.002]
Figure 4
7. CRIMP HEIGHT ADJUSTMENT (Figure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
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.
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
2. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. 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,
CRIMP HEIGHT ADJUSTMENT.
3. Refer to Section 5, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
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.89
[.035
"
"
2. With a screwdriver, adjust the ratchet wheel
from the locator side of the tool.
6. CRIMP HEIGHT INSPECTION
i
.74
[.029
Figure 3).
7. Check the contact’s crimp height as described in
Section 6, CRIMP HEIGHT INSPECTION. If
necessary, adjust the crimp height as described in
Section 7, CRIMP HEIGHT ADJUSTMENT.
NOTE
DIM. (A) AND
TOLERANCE (+)
The crimped contact may stick in the crimping
area, but the contact can be easily removed by
i
CRIMP HEIGHT
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
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.
Tyco Electronics Corporation
Rev B
408-4031
PRO-CRIMPER III Hand Crimping Tool Assembly 58548-1
10. REPLACEMENT
Screwdriver
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:
Ratchet
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS
PO BOX 3608
HARRISBURG PA 17105–3608
Adjustment
Wheel
11.REVISION SUMMARY
Lockscrew
(Typ)
Since the previous release of this instruction sheet,
the following changes were made:
Figure 5
S The new TE logo was applied; and
S PRO–CRIMPER II was changed to
PRO–CRIMPER III throughout.
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.
Rev
B
Tyco Electronics Corporation
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