TE Connectivity PRO-CRIMPER III User manual

Instruction Sheet
PRO- CRIMPER* III Hand
Crimping Tool Assembly 58546- 2 408--8678
LOC B
1of 6
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
17 Mar 11 Rev Cwith Die Assembly 58545- 1
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.
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.
Front of Tool
Die Assembly
Moving Jaw
Ratchet
Adjustment
Wheel
Moving
Handle
Stationary
Handle
PRO--CRIMPER III Hand
Crimping Tool Frame
354940--1 (408--9930)
Pivot Pin
Back of Tool
(Wire Side)
Stationary Jaw
Wire
TE Die Assembly Product Family}Size
(AWG)
Strip Length
(mm [In.])
SOLISTRAND* Terminal (Standard) 22--14 4.37--5.16 [.172--.203]
5
8
5
4
5
1
SOLISTRAND Terminal (Standard) and
Butt Splice 12--10 6.35--7.14 [.25--.281]
58545--1 SOLISTRAND Terminal (Long Barrel) or
Butt Splice 22--14 6.35--7.14 [.25--.281]
SOLISTRAND Terminal Parallel Splice 22--14 7.94--8.73 [.312--.344]
}Contact the Tooling Assistance Center or Product Information (at the number listed below) for specific terminal and splice part numbers.
Figure 1
1. INTRODUCTION
PRO--CRIMPER III Hand Crimping Tool Assembly
58546--2 consists of Die Assembly 58545--1 and
PRO--CRIMPER III Hand Crimping Tool Frame
354940--1. The tool is used to crimp the terminals and
splices onto the wire size listed in Figure 1.
Read these instructions thoroughly before crimping
any terminals or splices.
Dimensions on this sheet are in millimeters [with
inch equivalents provided in brackets]. Figures
are for reference only, and are not drawn to scale.
ORIGINAL INSTRUCTIONS
NOTE
i

408- 8678
Rev C2 of 6
Figure 2
Upper Die
Lower Die
Indenters
Anvils
Die Retaining
Screws
Stationary Jaw
Reasons for revision are given in Section 9,
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
adjustable ratchet that ensures full crimping.
The tool frame holds a die assembly with three
crimping chambers. The die assembly features an
upper die and a lower die. Die retaining screws are
used to position and secure the dies in the tool frame.
3. DIE ASSEMBLY INSTALLATION AND REMOVAL
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the upper die in the stationary jaw of the
tool frame so that the largest indenter is facing
inward. See Figure 2.
3. Insert the die retaining screw through the
stationary jaw and through the die. Tighten the
screw just enough to hold the die in place. Do not
tighten the screw completely at this time.
4. Place the lower die in the moving jaw of the tool
frame so that the largest anvil is facing inward. See
Figure 2.
5. Insert the die retaining screw through the
moving jaw and through the die. Tighten the screw
just enough to hold the die in place. Do not tighten
the screw completely at this time.
6. Carefully close the tool handles, making sure
that the anvils and indenters align properly.
Continue closing the tool handles until the ratchet
has engaged sufficiently to hold the dies in place,
then tighten both die retaining screws.
7. To disassemble, open the tool handles until the
ratchet releases, remove the two die retaining
screws, and slide the dies out of the tool jaws.
4. CRIMPING PROCEDURE
Before using the tool, the crimping chambers and
tool ratchet should be inspected as specified in
Section 5, CRIMP HEIGHT INSPECTION, and
Section 6, RATCHET (Shut Height)
ADJUSTMENT.
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 terminal or splice and identify the
appropriate crimping chamber according to the wire
size markings on the dies. Refer to Figure 3 and
proceed as follows:
The crimping chamber marked “12--10” cannot be
used to crimp spade--type terminals.
1. Hold tool so that the back (wire side) is facing
you. Squeeze tool handles together until the
ratchet releases, then allow them to open fully.
NOTE
i
NOTE
i

408- 8678
3of 6Rev C
Figure 3
Terminal
Terminal Wire Barrel
Centered on Anvil of
Lower Die
Splice
Splice Wire Barrel
Centered on Anvil of
Lower Die
Brazed Seam
Positioned Toward
Indenter
Splice Wire Barrel
Centered on Anvil of
Lower Die
Parallel Splice
Stripped
Wire
2. Center the terminal or splice wire barrel on the
anvil of the upper die as shown in Figure 3. If
visible, be sure to place the brazed seam on the
terminal or splice toward the indenter.
3. Hold the wire barrel in place and squeeze the
tool handles together until ratchet engages
sufficiently to hold the terminal or splice in position.
Do NOT deform the insulation barrel or wire barrel.
4. Insert stripped wire into the wire barrel, making
sure that the insulation does not enter the wire
barrel. See Figure 3.
5. Holding wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open, then remove crimped terminal or splice.
6. To crimp the other half of a splice, reposition the
uncrimped wire barrel in the crimping chamber, and
repeat the crimping procedure.
If splice cannot be turned for crimping the other
half, turn the tool around.
7. Inspect the crimped terminal or splice according
to Figure 4. Check the crimp height as described in
Section 5. If necessary, adjust the ratchet (shut
height) as described in Section 6.
Damaged terminals and splices may not be used.
If a damaged terminal or splice is evident, it must
be replaced with a new one.
5. CRIMP HEIGHT INSPECTION
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 5.
TE does not manufacture or market these gages.
To gage the crimping chamber, proceed as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Close the tool handles until the dies have
bottomed. Do NOT force dies beyond initial
contact.
3. Align the GO element with the crimping
chamber. Push element straight into the crimping
chamber without using force.
The GO element must pass completely through the
crimping chamber. See Figure 5.
4. Align the NO--GO element and try to insert it
straight into the same crimping chamber. The
NO--GO element may start entry, but must not
pass completely through the crimping chamber.
SeeFigure5.
NOTE
i
CAUTION
!

408- 8678
Rev C4 of 6
1
3
2
4
Butt Splice
Inspection
Hole
Figure 4
2
4
3
1
3
3
4
3
2
4
1
3
Crimp is centered on wire barrel. It is acceptable for
crimp to be slightly off center, but NOT OFF THE END of
the wire barrel.
Wire size being used matches wire size range stamped
on terminal or splice and dies.
Wire insulation does not enter wire barrel.
Wire is flush with or extends slightly beyond end of wire
barrel. Wire is visible through inspection hole of splices.
Terminal
Parallel Splice
If the crimping chamber conforms to the gage
inspection, the tool is considered dimensionally
correct, and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If not, the tool must be
returned to TE for further evaluation and repair. Refer
to Section 8, REPLACEMENT.
For additional information regarding the use of a plug
gage, refer to instruction sheet 408--7424.
6. RATCHET(Shut Height) ADJUSTMENT (Figure 6)
The frame assembly ratchet mechanism features an
adjustment wheel with numbered settings. If the dies
do not bottom, adjust the ratchet as follows:
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the opposite side of the frame.
Su
g
g
e
s
ted
P
l
u
g
G
a
g
e
D
e
s
i
g
n
Die Closure
Co
n
f
i
g
u
r
a
t
i
o
n
12.7 [.50]
Min Typ
GO
Dim.
50.8 [2.00]
Min Typ
“R”
NO--GO
Dim.
“R”
Crim
p
in
g
Gage Element Dimensions
C
r
i
m
p
i
n
g
Chamber
(Die Marking) GO NO--GO “R”
(Radius)
22--16 1.143--1.151
[.0450--.0453]
1.344--1.346
[.0529--.0530] 1.57 [.062]
16--14 1.346--1.354
[.0530--.0533]
1.547--1.549
[.0609--.0610] 1.98 [.078]
12--10 1.905--1.913
[.0750--.0753]
2.106--2.108
[.0829--.0830] 2.77 [.109]
F
i
g
u
r
e5
NO--GO Element May Start Entry, But Must Not
Pass Completely Through Crimping Chamber
GO Element Must Pass Completely
Through Crimping Chamber
3. Observe the ratchet adjustment wheel. If the
dies do not bottom, rotate the adjustment wheel
COUNTERCLOCKWISE to a higher--numbered
setting.
4. Replace the lockscrew.

408- 8678
5of 6Rev C
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew
Figure 6
7. MAINTENANCE AND INSPECTION
7.1. 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.
7.2. Visual Inspection
The die assembly 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 or dies must be
replaced. See Section 8, REPLACEMENT.
8. 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
717--986--7605, or write to:
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
For tool repair service, please contact a TE
Representative at 1--800--526--5136.
9. REVISION SUMMARY
Revisions to this instruction sheet include:
SUpdated document to corporate requirements.

408- 8678
Rev C6 of 6
PRO-CRIMPER III Hand Tool Frame 354940- 1
with Die Set 58545-1
(Instruction Sheet 408-9930)
SDE PEW- 12 Hand Tool 9-1478240-0
with Die Set 58545-1
(Instruction Sheet 408-8851)
SDE Bench Terminator 1490076- 2
with Die Set 58545-3
(Customer Manual 409-10052)
626 Adapter 679304-1
with Die Set 58545-4
(Instruction Sheet 408-4070)
Battery Tool (Shouldered Die) 1725837-1, -2
with Die Set 58545-3
(Customer Manual 409-10053)
Battery Tool (Pin Die) 1213890- 1, - 2
(Customer Manual 409-10065)
Die Assembly 58545- [ ] Can Also Be Used With the Following Tools: