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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.
408-4064
Adjustment Screw
(See Figure 3)
Tool Frame
(or Bench
Machine, or
Ratched Hand
Tool)
Die
Retaining
Pins
Nut
Nut
Washer
Locator
Insulation
Crimper
Chamfer
Wire
Crimper
Insulation
Anvil
Die Retaining Screws
Wire Anvil
Chamfer
Figure 2
Offset
Die retaining pins and die retaining screws are used to
position and secure the dies in the tool frame. A
washer and nut is used on the lower die retaining
screw to hold the locator in place.
3. INSTALLATION AND REMOVAL OF DIE SET AND
LOCATOR ASSEMBLY
(Figure 2)
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the wire anvil and insulation anvil in the
moving jaw so that their chamfered sides and
their marked surfaces face outward, when
mounted in the moving jaw of the tool frame.
3. Insert the two die retaining pins.
4. Insert the long die retaining screw through the
jaw and through both anvil dies, and tighten the
screw just enough to hold the dies in place. Do
not tighten the screw completely at this time.
5. Place the wire crimper and insulation crimper
in the stationary jaw so that their chamfered sides
and their marked surfaces face outward, when
mounted in the stationary jaw of the tool frame.
6. Insert the two die retaining pins.
7. Insert the short die retaining screw through the
jaw and through both crimper dies, and tighten
the screw just enough to hold the dies in place.
Do not tighten the screw completely at this time.
Rev
F
8. Carefully close the tool handles, making sure
that the anvils and crimpers align properly.
Continue closing the tool handles until the ratchet
in the tool frame has engaged sufficiently to hold
the anvils and crimpers in place, then tighten both
die retaining screws.
9. Place the locator over the end of the long
screw, and position the locator against the side of
the tool jaw.
10. Place the washer and nut onto the end of the
long screw. Align the locator slot with the
crimping section and carefully tighten the nut.
11. To disassemble, close the tool handles until
the ratchet releases, remove the nut, the washer,
the locator, the two die retaining screws, and the
four die retaining pins, and slide the anvils and
crimpers out of the tool jaws.
4. CRIMPING PROCEDURE
NOTE
i
This tool is provided with a crimp adjustment
feature. Initially, the crimp height should be verified
as specified in Figure 4. Refer to Section 6, Crimp
Height Inspection, and Section 7, Crimp Height
Adjustment, to verify crimp height before using the
tool to crimp desired contacts and wire sizes.
2
of 5
408-4064
Refer to the table in Figure 1 and select wire of the
specified size and insulation diameter. Strip the wire to
the length indicated in Figure 1, taking care not to nick
or cut wire strands. Select an applicable contact and
identify the appropriate die assembly according to the
wire size markings on the die. Refer to Figure 3 and
proceed as follows:
1. Hold the tool so that the back (wire side) is
facing you. Squeeze tool handles together and
allow them to open fully.
2. Holding the contact by the insulation barrel,
insert the contact—mating end first—into the
locator slot. Position the contact so that the open
“U” of the wire and insulation barrels face the top
of the tool. Make sure the contact butts against
the adjustment screw. Check that the contact is
centered with the die assembly wire and
insulation anvils. If adjustment is required, refer to
Section 5, CONTACT SUPPORT ADJUSTMENT.
NOTE
Make sure that both sides of the insulation barrel
are started evenly into the crimping section. Do not
attempt to crimp an improperly positioned contact.
4. Insert stripped wire into contact insulation and
wire barrels until it is butted against the wire stop
on the contact, as shown in Figure 3.
5. Holding the wire in place, squeeze tool handles
together until ratchet releases. Allow tool handles
to open and remove crimped contact.
6. Check the contact's crimp height as described
in Section 6, Crimp Height Inspection. If
necessary, adjust the crimp height as described
in Section 7, CRIMP HEIGHT ADJUSTMENT.
5. CONTACT SUPPORT ADJUSTMENT
(Figure 3
)
1. .Make a sample crimp according to Section 4,
CRIMPING PROCEDURE. If the crimp is out of
alignment, adjustment is required.
2. To move the contact from side-to-side, loosen
the nut that holds the locator to the frame and
slide the locator until the contact is properly
positioned. Hold the locator in place and tighten
the nut.
3. To move the contact in or out, loosen the nut
on the adjustment screw and turn the screw until
the contact is properly positioned. Hold the screw
in place and tighten the nut.
4. If the crimp is still out of alignment, repeat the
adjustment procedure.CRIMP HEIGHT
INSPECTION.
i
3. Hold the contact in position and squeeze the
tool handles together until ratchet engages
sufficiently to hold the contact in position. Do
NOT deform insulation barrel or wire barrel.
NOTE
The ratchet has detents that create audible clicks
as the tool handles are closed.
i
Back of Tool
(Wire Side)
Adjustment
Screw
“A”
Strip
Length
Locator
Wire Inserted to
Contact Wire Stop
TOOL
Wire Inserted
in Contact
DIMENSION A
2.641 [.104]
4.191 [.165]
Locator Slot
Wire
58517-1, 58517-2,
58517-3, 58517-4
58517-5
Figure 3
Rev
F
3
of 5
408-4064
.
Screwdriver
WIRE SIZE
AWG (Max)
22
CRIMP SECTION
(WIRE SIZE
MARKING)
26-22
Figure 4
CRIMP HEIGHT
DIM (A) AND
TOLERANCE (±)
0.79±0.05
[.031±.002]
Ratchet
Adjustment
Pawl
Lockscrew
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.
Tyco Electronics 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 4 and select a wire (maximum
size) for the crimp section.
2. Refer to Section 4, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
3. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. If
the crimp height conforms to that shown in the
table, the tool is considered dimensionally
correct. If not, the tool must be adjusted. Refer to
Section 7, CRIMP HEIGHT ADJUSTME
Figure 5
8. 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.
9. VISUAL INSPECTION
The crimping dies should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimp section for flattened,
chipped, worn, or broken areas. If damage or
abnormal wear is evident, the tool must be replaced.
See Section 10, REPLACEMENT.
10. REPLACEMENT
Customer-replaceable parts are shown in Figure 1.
Available separately, PRO-CRIMPER III Hand 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 1-
717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
7. .CRIMP HEIGHT ADJUSTMENT
(Figure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel
from the locator side of the tool.
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.
4. Replace the lockscrew.
5. Make a sample crimp and measure the crimp
height. If the dimension is acceptable, replace
and secure the lockscrew. If the dimension is
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp.
Rev
F
11. REVISION SUMMARY
Since the previous release of this sheet, the following
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