TE Connectivity PRO-CRIMPER III User manual

©2013 Tyco Electronics Corporation, a TE Connectivity Ltd. company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners.
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Instruction Sheet
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.te.com
408-4051
PRO-CRIMPER* III Hand Crimping
Tool Assembly 58541-1
with Die Assembly 58541-2 11 NOV 13 Rev D
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.
Figure 1
1. INTRODUCTION
PRO-CRIMPER III Hand Crimping Tool Assembly
58541-1 consists of Die Assembly 58541-2 and
PRO-CRIMPER III Hand Crimping Tool Frame
354940-1. The die assembly consists of crimping dies
and a locator assembly. Refer to Figure 1.
Read these instructions thoroughly before crimping
any contacts.
NOTE
Dimensions on this sheet are in millimeters [with inch
equivalents provided in brackets]. Figures and
illustrations are for identification only and are not drawn
to scale.
Front of Tool
Locator Side)
Die Assembly
Moving Jaw
Ratchet
Adjustment
Wheel
Stationary Jaw
Back of Tool
(Wire Side) PRO-CRIMPER III Hand
Crimping Tool Frame
354940-1 (See Instruction
Sheet 408-9930)
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
toolsin theappropriate 114application specification, but maynot comply with other featureparameters
of the specification. TE Connectivity offers a variety of tools to satisfy your performance requirements.
For additional information, contact the Tooling Assistance Center at 1-800-722-1111.
Pivot Pin
DIE ASSEMBLY
PART NUMBER
LOCATOR
ASEMBLY PART
NUMBER†
CONTACT
FAMILY‡
WIRE
SIZE
(AWG)
INSULATION
DIAMETER
(mm [in.])
STRIP LENGTH
(mm [in.])
58541-2 189382-1 67 MULTIMATE* Type II Series
Contacts
24-20 1.40 to 2.16
[.055 to .085] 5.32 [.209]
18-14 Open 6.35
[.250]
† Supplied with the die assembly. Also available separately. ‡Contact the ProductInformation Center (below) for specific contact part numbers.
NOTE
i
ORIGINAL INSTRUCTIONS

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Rev D
Figure 2
Reasons for reissue are provided in Section 10,
REVISION SUMMARY.
2. DESCRIPTION (Figure 1 and Figure 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 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.
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 lower 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 long 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 die retaining pins.
7. Insert the short 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.
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.
Nut Locator
Assembly
Locator
Tool Frame
DieRetaining
Pins
DieRetaining
Screws
Chamfer
WireCrimper
189457-1
Wire Anvil
189455 Insulation Anvil
189454-1
Chamfer Insulation
Crimper
189456-1
Chamfer

408-4051
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Rev D
Figure 3
4. CRIMPING PROCEDURE
NOTE
This tool is provided with a crimp adjustment feature.
Initially, the crimp height should be verified as specified
in Figure 4. Refer to Section5, Crimp Height Inspection,
and Section 6, Crimp height Adjustment, to 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. Refer to
Figure 3. Butt the contact shoulder against the
locator.
CAUTION
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. Fully insert the stripped wire into the contact as
shown in Figure 3.
6. While holding the wire in place, squeeze the tool
handles together until ratchet releases. Allow the
tool handles to open, and remove the crimped
contact.
7. Check the contact's 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
This inspection requires the use of a micrometer with a
modified anvil.
NOTE
TE does not manufacture or market these gages.
However, TE recommends the modified micrometer
(Crimp Height Comparator RS-1019-5LP).
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum
size) for each crimp section listed.
2. Refer to Section 4, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
Contact (Typ)
Strip Length
WireInserted
In Contact
ContactShoulder
Against Locator
Backof Tool
(Wire Side)
Locator
Wire
NOTE
i
!
NOTE
i

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Rev D
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 6,
CRIMP HEIGHT ADJUSTMENT.
Figure 4
6. 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. 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.
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.
Figure 5
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 crimp sections 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 the repair
kit and replaceable parts through your TE
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 (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
10. REVISION SUMMARY
•Updated document to corporate requirements
•Changed wire size marking in table in Figure 4
WIRE SIZE
AWG (MAX)
CRIMP SECTION
(WIRE SIZE
MARKING)
CRIMP HEIGHT
DIM. (A) AND
TOLERANCE (±)
20 24-20 1.09 ±0.051
[.043 ±.002]
14 18-16-14 1.60 ±0.051
[.063 ±.002]
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
(Typ)