Pro'sKit 902-138 CrimPro Crimper

1. Introduction

Thank you for choosing the Pro'sKit 902-138 CrimPro Crimper. This manual provides essential information for the safe and effective use, maintenance, and troubleshooting of your new crimping tool. Please read this manual thoroughly before operation and retain it for future reference.

2. Safety Information

Always observe basic safety precautions when using hand tools to reduce the risk of personal injury or damage to the tool. This product is intended for professional and DIY use in crimping open barrel contacts.

• Always wear appropriate personal protective equipment, such as safety glasses, when operating the crimper.
• Ensure the correct crimping die is selected for the specific terminal and wire gauge being used.
• Keep hands and fingers clear of the crimping jaws during operation.
• Do not use the tool for purposes other than its intended use (crimping open barrel contacts).
• Do not apply excessive force beyond the tool's design limits.
• Keep the tool clean and dry. Store it in a safe place away from children.
• WARNING: This product can expose you to chemicals including lead, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

3. Product Overview

The Pro'sKit 902-138 CrimPro Crimper is a precision tool designed for crimping open barrel contacts. It features a durable construction with comfortable handles and interchangeable dies for versatility.

Figure 3.1: The Pro'sKit 902-138 CrimPro Crimper, a multicolor tool with ergonomic handles, designed for open barrel contacts.

Key Features:

• Interchangeable Dies: Allows for crimping various sizes of open barrel contacts.
• Ratchet Mechanism: Ensures a complete crimp cycle for consistent, high-quality connections.
• Adjustable Crimping Force: A dial allows for fine-tuning the crimping pressure.
• Quick Release Lever: For easy release of the crimper jaws if needed.
• Ergonomic Handles: Designed for comfortable and secure grip during prolonged use.

Figure 3.2: Front view of the crimping dies, showing markings for 0.5-1.0mm², 1.5-2.5mm², and 4-6mm² wire sizes, corresponding to 20-18 AWG, 16-14 AWG, and 12-10 AWG respectively.

Figure 3.3: Detail of the integrated ratchet mechanism, which ensures a full crimp cycle for reliable connections.

Figure 3.4: The quick release lever, positioned for easy access, allows for immediate opening of the crimping jaws at any point during the crimp cycle.

Figure 3.5: The adjustment dial, marked with '+' and '-' symbols, allows users to fine-tune the crimping force for optimal results with different materials.

4. Setup

The Pro'sKit 902-138 CrimPro Crimper comes with pre-installed dies. If you need to change or inspect the dies, follow these steps:

1. Ensure the crimper is fully open.
2. Locate the small screw on the side of the crimper that secures the dies.
3. Use an appropriate screwdriver to loosen and remove the screw.
4. Carefully remove the existing dies.
5. Insert the desired new dies, ensuring they are correctly aligned with the crimper body and the screw holes.
6. Reinsert and tighten the screw to secure the dies firmly in place. Do not overtighten.

Figure 4.1: The crimper with one die removed and the securing screw visible, illustrating the process for die replacement.

5. Operating Instructions

Follow these steps for proper crimping:

1. Select Correct Die: Identify the appropriate crimping cavity on the dies that matches the size of your open barrel terminal and wire gauge. Refer to the markings on the dies (e.g., 0.5-1.0mm², 20-18 AWG).
2. Prepare Wire: Strip the insulation from the end of the wire to the correct length, exposing the conductor. Ensure the stripped length is suitable for the terminal being used.
3. Insert Terminal: Place the open barrel terminal into the selected crimping cavity. Ensure it sits securely.
4. Insert Wire: Insert the stripped wire into the terminal. Make sure all wire strands are within the terminal's crimp area.
5. Crimp: Squeeze the handles of the crimper firmly and steadily. The ratchet mechanism will engage, preventing the jaws from opening until a complete crimp cycle is achieved. Continue squeezing until the handles release automatically.
6. Inspect Crimp: After the crimp is complete, release the handles and remove the crimped terminal. Visually inspect the crimp for proper formation, ensuring the wire is securely held and the insulation crimp (if applicable) is correctly formed.
7. Adjust Crimping Force (if needed): If the crimp is too loose or too tight, use the adjustment dial (Figure 3.5) to increase or decrease the crimping force. Turn towards '+' for more force, and towards '-' for less force. Test on a scrap piece of wire and terminal.

6. Maintenance

Proper maintenance will extend the life of your Pro'sKit Crimper:

• Cleaning: After each use, wipe down the tool with a clean, dry cloth to remove any dirt, dust, or debris. For stubborn grime, a slightly damp cloth can be used, followed by immediate drying.
• Lubrication: Periodically apply a light coat of machine oil to the pivot points and moving parts to ensure smooth operation and prevent rust.
• Storage: Store the crimper in a dry environment to prevent corrosion. Keep it in its original packaging or a tool box to protect it from damage.
• Inspection: Regularly inspect the crimping dies for wear or damage. Worn dies can lead to poor crimps. Replace dies if they show signs of significant wear or deformation.

7. Troubleshooting

8. Specifications

9. Warranty and Support

For warranty information and technical support, please refer to the documentation included with your purchase or visit the official Pro'sKit website. Keep your proof of purchase for any warranty claims.

For further assistance, you may contact the seller, Eclipse Tools, or Pro'sKit directly through their official channels.