TE Connectivity PRO-CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand Crimping
Tool Assembly 58448- 2 408--9357
LOC B
1of 5
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
TE logo is a trademark.
*Trademark. Other product names, logos, or company names might be trademarks 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 at www.te.com
10 Mar 11 Rev EWith Die Assembly 58448- 3
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.
Stationary Jaw
Pivot Pin
PRO--CRIMPER III Hand Crimping
Tool Frame 354940-- 1 (408--9930)
Back of Tool
(Wire Side)
Stationary Handle
Movable Handle
Locator
Assembly
Front of Tool
(Locator Side)
Die Assembly
Moving Jaw
Ratchet Adjustment
Wheel
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
the appropriate 114 series specification, but may not comply with other feature
parameters of the specification. TE offers a variety of tools to satisfy your
performance requirements. For additional information, contact the Tooling
Assistance Center at 1 -- 800 -- 722 --1111.
T
E
D
i
e
L
o
c
a
t
o
r
Wire
TE Die
Assembly
Locator
Assembly{Product Family}Size Range
(AWG)
Insulation Diameter (Max)
(mm [in.])
Strip Length
(mm [in.])
5
8
4
4
8
3
1
2
1
4
3
1
0
1
AMPLIMITE*
HDP--20 Connector 28--24 1.02 [.040]
2
5
4
[
1
0
0
]
58448--3 1214310--1
H
D
P
-
-
2
0
C
o
n
n
e
c
t
o
r
Crimp Snap--In Contacts
with Insulation Support 24--20 1.52 [.060]
2.54 [.100
]
{Supplied with die assembly. Also available separately.
}Contact the Tooling Assistance Center or Product Information at the numbers listed below for specific contact part numbers.
Figure 1
1. INTRODUCTION
PRO--CRIMPER III Hand Crimping Tool Assembly
58448--2 consists of Die Assembly 58448--3 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 in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 10, REVISION SUMMARY.
2. DESCRIPTION
The tool features a tool frame with a stationary jaw
and handle, moving jaw, moving handle, and
adjustable ratchet that ensures full contact crimping.
The tool frame holds a die assembly with two
crimping chambers. See Figure 1.
The die assembly features a wire anvil, insulation
anvil, wire crimper, and insulation crimper.
Die retaining pins and die retaining screws are used
to position and secure the dies in the tool frame.
Attached to the outside of the frame is a locator
assembly, which contains a locator and contact
retainer. A nut is used on the upper die retaining
screw to hold the locator assembly in place.
NOTE
i

408- 9357
Rev E2 of 5
Locator
Assembly
Figure 2
Short Die Retaining
Screw
Long Die Retaining
Screw
Short Die
Retaining Pins
Long Die Retaining Pins
(Supplied with Locator Assembly)
Tool Frame
Nut
Locator
Chamfered
Edge
Wire Crimper
Offset
Wire Anvil
Insulation
Anvil
Insulation
Crimper
Chamfered
Edge
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY
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
the chamfered sides and marked surfaces face
outward, when mounted in the moving jaw of the
tool frame.
3. Insert the two short die retaining pins through
the tool frame and into the anvils.
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. 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 long die retaining pins (supplied
with the locator assembly) through the tool frame
and into the crimpers.
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. Remove the pin from the center hole in the
locator assembly. Place the locator assembly over
the end of the long die retaining screw and long die
retaining pins. 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.
4. CRIMPING PROCEDURE
This tool is provided with a crimp adjustment
feature. Initially, the crimp height should be
verified as specified in Section 5, CRIMP
HEIGHT INSPECTION, and Section 6,
RATCHET (Crimp Height) ADJUSTMENT, before
using the tool to crimp desired contacts.
Refer to Figure 1, and select wire of the specified size
and insulation diameter. Strip the wire to the length
indicated, taking care not to nick or cut wire strands.
Select an applicable contact and identify the
appropriate crimping chamber according to the wire
size markings on the tool.
Refer to Figure 3, and proceed as follows:
NOTE
i

408- 9357
3of 5Rev E
1. Hold the tool so that the front (locator side) is
facing you. Squeeze tool handles together and
allow them to open fully.
2. Insert the contact—mating end first—into the
hole in the locator which corresponds with the
appropriate crimping chamber. Make sure that the
open “U” of the wire barrel and insulation barrel
face the stationary jaw.
Do NOT attempt to close the tool handles when
locator contact retainer is between the dies.
Damage to the tool jaws or locator may result.
3. Slide the locator contact retainer out from
between the dies (spring tension will pull the
locator down). Make sure that the wire stop enters
the contact wire stop slot between the wire barrel
and contact shoulder. Release contact retainer.
Make sure that both sides of the contact
insulation barrel are started evenly into the
crimping chamber. 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. 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.
The crimped contact may stick in the crimping
area, but can be removed by pushing downward
on the top of the locator (see Figure 3).
7. Check the contact 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
Crimp height inspection is performed through the use
of a micrometer with a modified anvil, commonly
referred to as a crimp--height comparator. TE does
not manufacture or market crimp--height comparators.
Detailed information on obtaining and using
crimp--height comparators can be found in instruction
sheet 408--7424.
Proceed as follows:
1. Refer to Figure 4 and select the maximum size
wire for the crimping chamber.
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the contact 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, the tool is
considered dimensionally correct. If not, the tool
must be adjusted. Refer to Section 6, CRIMP
HEIGHT ADJUSTMENT.
Figure 3
Wire Strip Length
Locator in
Contact Wire
Stop Slot
Wire Inserted to
Locator Wire Stop
Tool Stationary
Jaw
Wire
Tool Wire
Size Markings
Back of Tool
(Wire Side)
Contact
Retainer
Locator
CAUTION
!
CAUTION
!
NOTE
i

408- 9357
Rev E4 of 5
Position Point
on Center of
Wire Barrel
Opposite
Seam Spindle
Modified
Anvil
Crimp
Height
Wire Size (AWG)
(Max)
Crimp Height Dimension
+0.05 mm [+.002 in.]
24 0.724 [.0285]
20 0.749 [.0295]
Figure 4
6. 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.
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. Re--assemble the lockscrew.
5. Make a sample crimp and measure the crimp
height.
6. If the dimension is unacceptable, continue to
adjust the ratchet, and again measure a sample
crimp.
F
i
gu
r
e5
Screwdriver
Ratchet Adjustment
Wheel
Lockscrew
(Typ)
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.
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 crimping chambers 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 repair kit and replaceable parts through your
TE representative, or call 1--800--526--5142, or send a
facsimile of your purchase order to 717--986--7605, or
write to:
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS
PO BOX 3608
HARRISBURG PA 17105--3608
10. REVISION SUMMARY
Revisions to this instruction sheet include:
SUpdated document to corporate requirements.

408- 9357
5of 5Rev E
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 58448-3 Can Be Used In the Following Tools: