Instruction Sheet
PRO-CRIMPER* III Hand Crimping
408-4276
Tool Assembly 58612-1 with
Die Assembly 58612-2
19 MAY 09
Rev A
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 Assembly
Stationary Jaw
(Supplied with
Die Assembly)
Back of Tool
(Wire Side)
Front of Tool
(Locator Side)
Pivot Pin
PRO-CRIMPER III Hand
Crimping Tool Frame
Die Assembly
354940-1
(408-9930)
Moving Jaw
Ratchet Adjustment Wheel
Stationary Handle
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
Moving Handle
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
Part Number
TE Locator
Part Number
C
Contact
{
Family
}
Size
2
mm
58515-1
Supplied with die assembly, also available separately.
}
(mm [in.])
2.15
0.35
{
Strip Length
[.085]
0.6
MT2 Receptacles
Dia.
(mm [in.])
1.0
58612-2
Insulation
1.90
2.937 - 3.23
[.075]
[.116 - .127]
1.40
[.055]
Contact the Tooling Assistance Center or the Product Information Center (below) for
specific contact numbers.
Figure 1
Read these instructions thoroughly before crimping
any contacts.
1. INTRODUCTION
PRO–CRIMPER III Hand Crimping Tool
Assembly 58612–1 consists of Die Assembly
58612–2 and PRO–CRIMPER III Hand Crimping
Tool Frame 354940–1.
The die assembly consists of crimping dies and a
locator assembly.
E
2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
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 revision can be found 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
408-4276
PRO-CRIMPER III Hand Crimping Tool Assembly 58612-1
Locator
Nut
Tool Frame
Assembly
Insulation
Die Retaining Pins
Crimper
Chamfer
Wire Crimper
Offset
Wire Anvil
Chamfer
Insulation Anvil
Die Retaining Screws
Figure 2
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
adjustable ratchet that ensures full contact crimping.
The tool frame holds a die assembly with three
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)
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.
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
9. Place the locator assembly over the end of the
long screw, and position the locator assembly
against the side of the tool jaw.
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.
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.
3. Insert the two die retaining pins.
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. Insert the short die retaining screw through the
moving jaw and through both anvil dies, and
tighten the screw just enough to hold the dies in
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Tyco Electronics Corporation
Rev
A
408-4276
PRO-CRIMPER III Hand Crimping Tool Assembly 58612-1
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
NOTE
feature. Initially, the crimp height should be
1. Make a sample crimp and determine if the
contact is straight, bending upward, or bending
downward.
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.
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.
5. Move the contact support as required to
eliminate the bending of the contact.
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
must 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.
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
Support
6, CRIMP HEIGHT INSPECTION, and Section 7,
height before using the tool to crimp desired
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
Contact
verified as specified in Figure 4. Refer to Section
CRIMP HEIGHT ADJUSTMENT, to verify crimp
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
Locator
Back of Tool
(Wire Side)
Adjustment
Contact
Screw for
(Typ)
Contact
Strip Length
Support
Wire
Locator in Wire
Stop Slot
Wire Inserted
to Stop
Figure 3
Rev
A
Tyco Electronics Corporation
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408-4276
PRO-CRIMPER III Hand Crimping Tool Assembly 58612-1
CAUTION
!
Make sure that both sides of the insulation barrel
Position Point
are started evenly into the crimping section. Do
on Center of
NOT attempt to crimp an improperly positioned
Wire Barrel
contact.
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.
Seam
Modified Anvil
A"
WIRE SIZE
2
mm
CRIMP SECTION
(MAX)
(WIRE SIZE MARKING)
1.0
1.0
0.6
0.6
CRIMP HEIGHT
DIM (A) AND
DIM.
TOLERANCE (+)
1.50
[.059
1.32
[.052
NOTE
The crimped contact may stick in the crimping
area, but the contact can be easily removed by
i
0.35
0.35
pushing downward on the top of the locator (see
.05
.002]
.05
.002]
7. 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.
6. CRIMP HEIGHT INSPECTION
This inspection requires the use of a micrometer with
a modified anvil.
i
.05
.002]
Figure 4
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
1.22
[.048
"
"
"
"
"
"
Screwdriver
Tyco Electronics does not manufacture or market
these gages,. TE recommends the the use of the
modified micrometer (Crimp Height Comparator
RS-1019-5LP) OR the digital Mitutoyo
micrometer.
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
Ratchet
Adjustment
Wheel
2. Refer to Section 5, 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
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.
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Tyco Electronics Corporation
Lockscrew
(Typ)
Figure 5
Rev A
408-4276
PRO-CRIMPER III Hand Crimping Tool Assembly 58612-1
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.
8. MAINTENANCE
10. REPLACEMENT
Customer–replaceable parts are shown in Figure 1. If
the dies are damaged or worn excessively, they must
be replaced.
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.
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
P.O. BOX 3608
HARRISBURG, PA 17105–3608
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.
11.REVISION SUMMARY
9. VISUAL INSPECTION
Since the previous release of this instruction sheet,
the following changes have been made:
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 A
S PRO–CRIMPER II hand tool was changed to
the PRO–CRIMPER III hand tool;
S The TE logo has been applied; and
S The format has been updated to the current
corporate requirements.
Tyco Electronics Corporation
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