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ORIGINAL INSTRUCTIONS
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.
408-4007
Locator Assembly
Tool Jaws
Nut
Locator
Wire Crimper
Die
Chamfer
Die Retaining Pin
(4 Places)
Long Die Retaining
Screw
Offset
Insulation
Crimper
Die
Wire Anvil
Die
Chamfer
Insulation Anvil
Die
Figure 2
Short Die Retaining
Screw
When closed, the dies form two crimping chambers.
Each die is held in the tool frame by a retaining screw
and two retaining pins.
9. Place the locator assembly over the end of the
long die retaining screw, and position the locator
assembly against the side of the tool jaw.
10. Place the nut onto the end of the long die
retaining 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, locator assembly,
the two die retaining screws, and four die retaining
pins, then, slide the dies out of the tool jaws.
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY
AND LOCATOR ASSEMBLY
1. Close the tool handles until the ratchet releases,
then allow the handles to open fully.
2. Remove the two die retaining screws from the
tool jaws.
3. Slide the wire anvil and insulation anvil dies onto
the moving jaw so that the chamfers and marked
surfaces face outward as shown in Figure 2, then
insert the two die retaining pins through the holes in
the moving jaw and into the holes in the dies.
4. Thread, but do not tighten, the short die retaining
screws through the holes of the moving jaw and into
the holes in both anvil dies.
5. Slide the wire crimper and insulation crimper dies
onto the stationary jaw so that the chamfers and
marked surfaces face outward as shown in Figure 2,
then insert the two die retaining pins through the holes
in the stationary jaw and into the holes in the dies.
6. Thread, but do not tighten, the long die retaining
screws through the holes of the moving jaw and into
the holes in both crimper dies.
7. Carefully close the tool handles, making sure that
the dies align properly. Continue closing the
handles until the ratchet has engaged sufficiently to
hold the dies in place.
8. Tighten the die retaining screws using the
appropriate screwdriver.
Rev
D
4. CRIMPING PROCEDURE
NOTE
i
The tool frame is provided with a crimp adjustment
feature. Initially, the crimp height should be verified
according to Section 6, CRIMP HEIGHT
INSPECTION, and if necessary, adjusted
according to Section 7, CRIMP HEIGHT
ADJUSTMENT before using the tool.
Refer to Figure 1, and select wire of the specified size
and insulation diameter. Strip the wire to the
dimension given in Figure 1, taking care not to nick or
cut wire strands. Then proceed as follows:
1. Hold the tool so that the back (wire side) faces
you. Close the tool handles until the ratchet
releases, then allow the handles to open FULLY.
2. Insert the contact (insulation barrel first) into the
front of the appropriate crimping chamber (refer to
the markings on the die).
3. Position the contact so that the mating end is on
the locator side of the tool frame and the open “U” of
the wire barrel and insulation barrel faces the top of
2
of 5
408-4007
Contact Support
Back of
Tool Frame
(Wire Side)
Crimping
Chamber
Wire Strip Length
Adjustment
Screw for
Contact Support
Wire
Locator in
Wire Stop Slot
of Contact
Wire Inserted
to Wire Stop
Figure 3
the tool frame. Place the contact up into the
crimping chamber so that the locator drops into the
slot in the contact. Refer to Figure 3. Butt the front
end of the wire barrel against the locator.
CAUTION
Proceed as follows:
1. Make a sample crimp and determine if the
contact is bending (upward or downward).
2. Loosen the screw that holds the contact support
onto the locator assembly.
3. Place a contact with a wire into the proper
crimping chamber, and close the tool handles until
the ratchet reaches the sixth click or until the
contact support touches the contact.
NOTE
!
Make sure that both sides of the 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 close the tool
handles until the ratchet engages sufficiently to hold
the contact in position. DO NOT deform the
insulation barrel or wire barrel.
5. Insert the stripped wire into contact insulation
barrel and wire barrel until it is butted against the
wire stop as shown in Figure 3.
6. Holding the wire in place, close the tool handles
until the ratchet releases.
7. Allow the tool handles to open FULLY, and
remove the crimped contact.
NOTE
The ratchet has detents that create audible clicks
as the tool handles are closed.
i
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
5. Move the contact support as required to eliminate
the bending of the contact.
6. Tighten the nut, then close the handles until the
ratchet releases.
7. Remove and inspect the contact. Make another
sample crimp. If the contact is straight, tighten the
contact support screw. If the contact is still being
bent during crimping, repeat the adjustment
procedure.
i
CAUTION
The crimped contact may stick in the crimping area;
however the contact can be removed by pushing
downward on the top of the locator (see Figure 3).
8. Check the contact crimp height, and if necessary,
adjust the crimp height
DO NOT use defective or damaged products.
5.2. Ratchet Adjustment
The tool ratchet mechanism features an adjustment
wheel with numbered settings. The adjustment wheel
controls the amount of handle pressure exerted on the
jaws during crimping. If the crimp is not acceptable,
adjust the ratchet as follows:
1. Remove the lockscrew from the ratchet
adjustment wheel. Refer to Figure 4.
2. Using a screwdriver, adjust the ratchet wheel
from the front of the tool.
3
of 5
!
5. ADJUSTMENTS
5.1. Contact Support
The contact support is preset prior to shipment, but
minor adjustment may be necessary if the contact is
bending during crimping.
Rev
D
408-4007
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.
Position Point on
Center of Wire Barrel
Opposite Seam
A
(See Table)
Screwdriver
CRIMPING
CHAMBER
MARKING
26-28
22-24
MAXIMUM
WIRE SIZE
(AWG)
26
22
Figure 5
DIMENSION A
CRIMP HEIGHT
(mm [in.])
0.69±0.05 [.027±.002]
0.79±0.05 [.031±.002]
Ratchet Adjustment
Wheel
Lockscrew
Figure 4
3. Remove all lubrication and accumulated film from
the dies by immersing the dies in a suitable
commercial degreaser.
7.2. Visual Inspection
4. Re-install the lockscrew.
5. Make a sample crimp. If the crimp is acceptable,
the adjustment setting is correct. If the crimp is
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp.
1. Inspection of the tool and dies should be made on
a regular basis to ensure that they have not become
worn or damaged.
2. Make sure that the proper die retaining screws
are properly secured.
3. Inspect the crimping chambers of the die
assembly for flattened, chipped, worn, or broken
areas. If damage or abnormal wear is evident, the
dies must be replaced. Refer to Section 7,
REPLACEMENT AND REPAIR.
6. 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
market crimp height comparators. Refer to Instruction
Sheet 408-7224 for detailed information on obtaining
and using a crimp height comparator.
Proceed as follows:
1. Refer to Figure 5, and select a maximum size
wire for each crimping chamber.
2. Crimp the contacts according to Section 4.
3. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. If the
crimp height conforms to the dimension, the tool
assembly is considered dimensionally correct. If
not, the tool frame must be adjusted. Refer to
Paragraph 5.2, Crimp Height Adjustment.
8. REPLACEMENT AND REPAIR
Available separately, 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, tool assembly, and die assembly
through your representative, or call 1-800-526-5142,
or send a facsimile of your purchase order to
717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
7. MAINTENANCE AND INSPECTION
7.1. Maintenance
1. Ensure that the tool frame and dies are clean by
wiping them with a clean, soft cloth. Remove any
debris with a clean, soft brush. Do not use objects
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