Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 90548-1 with 408-9885 Die Assembly 90548-2 02 NOV 12 Rev G 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 Back of Tool Assembly) (Wire Side) Front of Tool Pivot Pin (Locator Side) Die Assembly PRO-CRIMPER III Hand Crimping Tool Frame Moving Jaw 354940-1 (408-9930) 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, Moving Handle 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. This company offers a variety of tools to satisfy your performance requirements. For additional information, contact the Tooling Assistance Center at 1-800-722-1111. WIRE DIE LOCATOR CONTACT ASSEMBLY ASSEMBLY FAMILY SIZE (AWG) INSUL DIA STRIP LENGTH Universal 24-22 1.02 to 2.54 3.96 to 4.75 90548-2 58515-1 MATE-N-LOK* .040 to .100 .156 to .187 20-18 Contacts Supplied with die assembly. Also available separately Contact the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION (see below) for specific contact part numbers. Figure 1 1. INTRODUCTION Reasons for reissue are provided in Section 11, REVISION SUMMARY. PRO-CRIMPER III Hand Crimping Tool Assembly 90548-1 consists of Die Assembly 90548-2 and 2. DESCRIPTION (Figure 1 and Figure 2) PRO-CRIMPER III Hand Crimping Tool Frame 354940-1. The die assembly consists of crimping dies The tool features a tool frame with a stationary jaw and a locator assembly. and handle, a moving jaw, a moving handle, and an adjustable ratchet that ensures full contact crimping. Read these instructions thoroughly before crimping The tool frame holds a die assembly with two crimping any contacts. sections. Dimensions on this sheet are in millimeters with NOTE The die assembly features a wire anvil, an insulation inch equivalents provided in brackets . Figures and anvil, a wire crimper, and an insulation crimper. illustrations are for identification only and are not i drawn to scale. Attached to the outside of the frame is a locator assembly, which contains a locator, a spring retainer, and a contact support. 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS408-9885 Nut Locator Assembly Tool Frame Locator Insulation Die Retaining Crimper Chamfer Pins Wire Crimper Offset Wire Anvil Insulation Chamfer Die Retaining Anvil Screws Figure 2 Die retaining pins and die retaining screws are used to closing the tool handles until the ratchet in the tool position and secure the dies in the tool frame. A nut is frame has engaged sufficiently to hold the anvils used on the upper die retaining screw to hold the and crimpers in place, then tighten both die locator assembly in place. retaining screws. 9. Place the locator assembly over the end of the 3. INSTALLATION AND REMOVAL OF DIE SET AND long screw, and position the locator assembly LOCATOR ASSEMBLY (Figure 2) against the side of the tool jaw. 1. Open the tool handles and remove the two die 10. Place the nut onto the end of the long screw and retaining screws from the tool jaws. tighten the nut enough to hold the locator assembly 2. Place the wire anvil and insulation anvil so that in place, while still allowing the locator to slide up their chamfered sides and their marked surfaces and down. face outward, when mounted in the moving jaw of 11. To disassemble, close the tool handles until the the tool frame. ratchet releases, remove the nut, the locator 3. Insert the two die retaining pins. assembly, the two die retaining screws, and the four die retaining pins, and slide the anvils and crimpers 4. Insert the short die retaining screw through the out of the tool jaws. jaw and through both anvil dies, and tighten the screw just enough to hold the dies in place. Do not 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) tighten the screw completely at this time. 5. Place the wire crimper and insulation crimper so that their chamfered sides and their marked The contact support is preset prior to shipment, but NOTE surfaces face outward, when mounted in the minor adjustment may be necessary. stationary jaw of the tool frame. i 6. Insert the two die retaining pins. 1. Make a sample crimp and determine if the 7. Insert the long die retaining screw through the contact is straight, bending upward, or bending jaw and through both crimper dies, and tighten the downward. screw just enough to hold the dies in place. Do not 2. If adjustment is required, loosen the screw that tighten the screw completely at this time. holds the contact support onto the locator assembly. 8. Carefully close the tool handles, making sure that the anvils and crimpers align properly. Continue Rev G 2 of 6