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ORIGINAL INSTRUCTIONS
408-8580
3. Install the anvil dies in the movable jaw of the tool frame so that the chamfered edges and marked
surfaces face outward. Align the dies with the screw hole, then insert the two die retaining pins
included with the die assembly through the holes in the dies and into the holes in the tool frame.
4. Secure the anvil dies with the die retaining screw included with the die assembly. DO NOT fully tighten
the screw.
5. Install indenter dies in the stationary jaw of the tool frame so that the chamfered edges and marked
surfaces face outward. Align the dies with the screw hole, then insert the two die retaining pins
included with the die assembly through the holes in the dies and into the holes in the tool frame.
6. Secure the indenter dies with the die retaining screw included with the die assembly. DO NOT fully
tighten the screw.
7. Slowly close the tool handles, making sure that the dies align properly. After the anvil dies enter the
indenter dies, place a 1.57 ±0.05-mm [.062 ±.002-in.] diameter copper bus bar into the center contact
crimping chamber of the die assembly.
8. Continue closing the tool handles until the ratchet has engaged sufficiently to hold the dies in place,
then tighten both die retaining screws.
9. To remove the die assembly from the tool frame, close the tool handles until the ratchet releases,
remove the two die retaining screws and four die retaining pins, and slide the dies out of the jaws.
4. CRIMPING PROCEDURE
NOTE
Refer to the instructions included with the connector for cable preparation and connector assembly. Before proceeding, ensure
that the ferrule is on the cable and the braided shield is flared away from the cable.
NOTE
This tool frame has a crimp height adjustment feature. Initially, the crimp height should be verified. Make a sample crimp.
Refer to the instructions included with the connector for the acceptable crimp height. If the crimp height is unacceptable, refer
to Section 5 to adjust the crimp height.
4.1. Crimp the Center Contact
(Refer To Figure 2)
1. Close the tool handles until the die assembly is partially closed.
2. Assemble the center contact onto the center conductor of the cable, and place the center contact on
the anvil in the smallest crimping chamber. Make sure the flange on the end of the center contact
butts against the die.
3. Holding the cable in place, close the tool handles until the ratchet releases.
4. Allow the tool handles to open fully and remove the crimped center contact from the dies.
Crimping Center Contact
Flange of Center
Contact Butts
Against Die
Smallest
Crimping
Chamber of
Anvil Die
Cable
NOTE:
Die shown in PRO-CRIMPER III frame assembly.
Jack Center
Contact
Cross-Section View
Flange
Plug Center
Contact
Die
Flange
Die
Figure 2
Rev D
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408-8580
4.2. Crimp the Ferrule
(Refer To Figure 3)
1. Insert the crimped center contact into the connector body until the cable dielectric butts against the
dielectric inside the connector body or until the center contact is securely positioned within the
connector. Make sure that the braided shield of the cable is over the support sleeve of the connector
body and that no strands from the shield enter the connector body.
Crimping Ferrule
Shoulder of Connector
Body Butts Against Die
NOTE:
Die shown in PRO-CRIMPER III frame assembly.
Crimping Chamber
of Anvil Die
Figure 3
2. Slide the ferrule over the braided shield and onto the connector until the ferrule butts against the
shoulder of the connector body.
3. Place the ferrule in the appropriate crimping chamber of the anvil die so that the shoulder of the
connector body butts against the edge of the die.
NOTE
Refer to the instructions included with the connector to determine the appropriate crimping chamber.
4. While holding the assembly together, close the tool handles until the dies have closed enough to
secure the assembly in place.
CAUTION
Make sure that both sides of the ferrule are started evenly into the crimping chamber. DO not attempt to crimp an improperly
positioned ferrule.
5. Carefully close the tool handles until the ratchet releases, then allow the tool handles to open fully,
and remove the crimped connector from the dies.
5. CRIMP HEIGHT ADJUSTMENT
(Refer To Figure 4)
The tool frame ratchet mechanism features an adjustment wheel with numbered settings. If the crimp height is
not acceptable, adjust the ratchet as follows:
1. Remove the lockscrew from the ratchet adjustment wheel.
2. Using a screwdriver, rotate the ratchet adjustment wheel from the opposite side of the tool frame. If a
tighter crimp is required, rotate the ratchet adjustment wheel counterclockwise to a higher-numbered
setting. If a looser crimp is required, rotate the ratchet adjustment wheel clockwise to a lower-
numbered setting.
Screwdriver
Lockscrew
NOTE:
Die shown in PRO-CRIMPER III
frame assembly shown, refer to Instruction
Sheet 408-8851 for SDE-SA frame.
Ratchet
Adjustment
Wheel
Figure 4
Rev D
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408-8580
3. Re-install the lockscrew.
4. Make a sample crimp and measure the crimp height. If the crimp height is still unacceptable, remove
lockscrew and continue to adjust the ratchet.
CAUTION
Damaged product should not be used. If damage to the product is evident, it should be cut from the wire and replaced with
new product.
6. MAINTENANCE AND INSPECTION
The die assembly is inspected before shipment. It is recommended that the die assembly be inspected
immediately upon arrival at your facility to ensure that the dies have not been damaged during shipment.
The die assembly will perform correctly as long as: (1) the product specified is correct for the application, (2)
the proper die assembly is used, (3) the die assembly has been measured to ensure that the openings are
correct, and (4) the tool has been adjusted correctly.
6.1. Maintenance
1. Remove dust, moisture, and other contaminants with a clean, soft brush, or a clean, soft, lint-free
cloth. DO NOT use any objects that could damage the dies or tool.
2. Make sure that the proper die retaining screws are properly secured.
3. When the dies are not in use, store them in a clean, dry area.
6.2. Inspection
1. Remove all lubrication and accumulated film from the dies by immersing the dies in a suitable
commercial degreaser.
2. Make certain that die retaining screws and pins are properly secured.
3. Inspect the crimping surfaces for flattened, chipped, worn, or cracked areas. If damage is evident, the
dies must be replaced. Refer to Section 7, REPLACEMENT.
4. Measure the die opening to ensure that it meets the dimensions given in Figure 5.
7. REPLACEMENT
Order replacements through your local 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
8. REVISION SUMMARY
In Figure 5, changed Crimp Height Dimension of Die Assembly 91909-1 from 1.29 to 1.19 (marked
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