Instruction Sheet PRO-CRIMPER* III Hand Crimping Tool Assembly 90758-1 408-9938 with Die AssemblY 90758-2 01 NOV 11 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. Stationary Jaw Back of Tool Frame Locator Assembly (Wire Side) (Supplied with Die Assembly Front of Tool (Locator Side) Pivot Pin Die Assembly PRO-CRIMPER III Hand Tool Frame 354940-1 (408-9930) 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 Application Specification (114-series), but may not comply with other feature parameters of the specification. TE Connectivity offers a variety of tools to satisfy your performance requirements. Stationary Handle For additional information, contact the Tooling Assistance Center at 1-800-722-1111. Moving Handle WIRE TE DIE TE LOCATOR CONTACT ASSEMBLY ASSEMBLY FAMILY SIZE (AWG) INSUL DIA STRIP LENGTH Mini Universal 1.19-1.75 3.20 to 3.71 90758-2 58516-1 MATE-N-LOK* 26-22 .047-.069 .126 to .146 Connectors 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 2. DESCRIPTION (See Figures 1 and 2) PRO-CRIMPER III Hand Crimping Tool Assembly The tool consist of a stationary jaw and handle, a 90758-1 consists of Die Assembly 90758-2 and moving jaw and handle, and an adjustable ratchet that PRO-CRIMPER III Hand Crimping Tool Frame ensures full contact crimping. The tool frame holds a 354940-1 (see Instruction Sheet 408-9930). The die die assembly with two crimping sections. assembly consists of crimping dies and a locator The die assembly features a wire anvil, an insulation assembly. anvil, a wire crimper, and an insulation crimper. Read these instructions thoroughly before crimping Attached to the outside of the frame is a locator any contacts. assembly, which contains a locator, spring retainer, Dimensions in this instruction sheet are in and a contact support. NOTE millimeters with inch equivalents provided in Die retaining pins and die retaining screws are used to brackets . Figures and illustrations are for position and secure the dies in the tool frame. A nut is i reference only and are not drawn to scale. used on the upper die retaining screw to hold the Reasons for reissue of this instruction sheet are locator assembly in place. provided in Section 11, REVISION SUMMARY. 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 5 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 INSTRUCTIONS408-9938 Nut Locator Assembly Tool Frame Locator Chamfer Insulation Die Retaining Pins Crimper Wire Crimper Offset Wire Anvil Insulation Anvil Die Retaining Chamfer Die Retaining Screw Screw Figure 2 3. INSTALLATION AND REMOVAL OF DIE SET AND 10. Place the nut onto the end of the long screw and LOCATOR ASSEMBLY (Figure 2) tighten the nut enough to hold the locator assembly in place, while still allowing the locator to slide up 1. Open the tool handles and remove the two die and down. retaining screws from the tool jaws. 11. To disassemble, close the tool handles until the 2. Place the wire anvil and insulation anvil so that ratchet releases, remove the nut, the locator their chamfered sides and their marked surfaces assembly, the two die retaining screws, and the four face outward, when mounted in the moving jaw of die retaining pins, and slide the anvils and crimpers the tool frame. out of the tool jaws. 3. Insert the two die retaining pins. 4. CONTACT SUPPORT ADJUSTMENT (Figure 3) 4. Insert the short die retaining screw through the The contact support is preset prior to shipment, but jaw and through both anvil dies, and tighten the NOTE minor adjustment may be necessary. screw just enough to hold the dies in place. Do NOT tighten the screw completely at this time. i 5. Place the wire crimper and insulation crimper so 1. Make a sample crimp and determine if the that their chamfered sides and their marked contact is straight, bending upward, or bending surfaces face outward, when mounted in the downward. stationary jaw of the tool frame. 2. If adjustment is required, loosen the screw that 6. Insert the two retaining pins. holds the contact support onto the locator assembly. 7. Insert the long die retaining screw through the The ratchet has detents that create audible clicks jaw and through both crimper dies, and tighten the NOTE as the tool handles are closed. screw just enough to hold the dies in place. Do NOT tighten the screw completely at this time. i 8. Carefully close the tool handles, making sure that 3. Place a contact with wire into the proper nest and the anvils and crimpers align properly. Continue close the tool handles until the ratchet reaches the closing the tool handles until the ratchet in the tool sixth click, or until the contact support touches the frame has engaged sufficiently to hold the anvils contact. and crimpers in place, then tighten both die retaining screws. 4. Slightly loosen the nut that holds the locator assembly onto the tool frame. 9. Place the locator assembly over the end of the long screw, and position the locator assembly 5. Move the contact support as required to eliminate against the side of the tool jaw. the bending of the contact. Rev D 2 of 5