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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.
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2. DESCRIPTION
The tool frame features a stationary jaw and handle, a moving jaw and handle, and an adjustable ratchet that
ensures full crimping. The tool frame holds the die assembly. See Figure 1.
The die assembly consists of an anvil and indenter. When closed, the dies form three crimping chambers. The
indenter is marked with the letters R, B, and Y which correspond with the color of the terminal insulation (red,
blue, or yellow). Die retaining screws are used to secure the dies in the tool frame. See Figure 2.
Yellow
Blue
Back of Tool
Anvil
Indenter
Red
Die Retaining Screw (2 Places)
Figure 2
3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY
1. Close the tool handles until the ratchet releases, then allow the handles to open fully.
NOTE
The ratchet has detents that create audible clicks as the tool handles are closed.
2. Remove the two die retaining screws and die retaining pins (pins will not be used for this die
assembly) from the tool jaws.
3. Place the anvil in the moving jaw so that the marked surface faces outward. Insert the die retaining
screw through the hole of the moving jaw and hole of the anvil, and tighten the screw just enough to
hold the anvil in place. DO NOT completely tighten the screw.
4. Place the indenter in the stationary jaw so that the marked surface faces outward. Insert the die
retaining screw through the hole of the stationary jaw and hole of the indenter, and tighten the screw
just enough to hold the indenter in place. DO NOT completely tighten the screw.
5. Carefully close the tool handles, making sure that the anvil and indenter align properly. Continue
closing the tool handles until the ratchet engages sufficiently to hold the anvil and indenter in place,
then tighten both die retaining screws.
6. To disassemble, close the tool handles until the ratchet releases, remove the two die retaining screws,
then slide the dies out of the tool jaws.
4. CRIMPING PROCEDURE
This tool is provided with a crimp adjustment feature. Initially, the crimp height of a sample terminal should be verified in
accordance with Section 5.
Refer to 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.
1. Hold the tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them
to open fully.
2. Place the terminal in the proper crimping chamber (match color code to terminal insulation) so that the
edge of the insulation aligns with the edge of the indenter. The wire barrel should be at the back of the
tool.
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3. Hold the terminal in position, and squeeze the tool handles together until ratchet engages sufficiently
to hold the terminal. DO NOT deform the wire barrel.
4. Insert the stripped wire into the wire and holding the wire in place, squeeze the tool handles together
until the ratchet releases. Allow the tool handles to open, and remove the crimped terminal.
5. Inspect the terminal crimp height according to Section 5.
5. CRIMP HEIGHT INSPECTION
This inspection requires the use of calipers. A lead rod can be used to check the crimp height. Crimp a rod in
each of the crimping chambers. Check the crimp height of the rod against the crimp height dimension given in
Figure 4.
Terminal
Tongue
Anvil
Indenter
Back of Tool
Stripped Wire
Edge of Terminal
Insulation Aligned
with Edge of Anvil
Tool Jaws
Figure 3
6. CRIMP HEIGHT INSPECTION
This inspection requires the use of calipers. A lead rod can be used to check the crimp height. Crimp a rod in
each of the crimping chambers. Check the crimp height of the rod against the crimp height dimension given in
Figure 4.
LEAD ROD DIAMETER
4.8 [.19]
3.2 [.12]
3.2 [.12]
CRIMPING CHAMBER MARKING
Y (Yellow)
B (Blue)
R (Red)
Figure 4
CRIMP HEIGHT DIMENSION
3.35 ±0.15 [.132 ±.006]
2.44 ±0.15 [.096 ±.006]
2.08 ±0.15 [.082 ±.006]
If the crimp height conforms to the dimension, the tool and die assembly are considered dimensionally correct.
Lubricate the tool with a thin coat of any good SAE 20 motor oil. If it does not, adjust the crimp height according
to Section 6. If the adjustment does not result in acceptable crimp height, the die assembly or tool may have to
be replaced.
7. RATCHET ADJUSTMENT
(Figure 5)
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. Check the crimp height according
to Section 5. If the crimp height is not acceptable, adjust the crimp height as follows:
1. Remove the lockscrew from the ratchet adjustment wheel.
2. With a screwdriver, adjust the ratchet wheel from the front of the tool.
3. Observe the ratchet adjustment wheel. If a tighter (smaller) crimp height is required, rotate the
adjustment wheel counterclockwise to a higher-numbered setting. If a looser (larger) crimp height is
required, rotate the adjustment wheel clockwise to a lower-numbered setting.
4. Re-assemble the lockscrew.
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5. Make a sample crimp. If the crimp height is acceptable, the adjustment setting is correct. If the crimp
height is unacceptable, continue to adjust the ratchet, and again measure a sample crimp.
Screwdriver
Ratchet
Adjustment Wheel
Lockscrew
Figure 5
8. MAINTENANCE AND INSPECTION
8.1. Maintenance
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 that could damage any components. When not in use, keep tool handles
closed to prevent objects from becoming lodged in the dies, and store in a clean, dry area.
8.2. Visual Inspection
Inspection of the dies should be made on a regular basis to ensure that they have not become worn or
damaged. Inspect the crimping chambers for flattened, chipped, worn, or broken areas. If damage or abnormal
wear is evident, the dies must be replaced. Refer to Section 8, REPLACEMENT.
9. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 1. Available separately, Repair Kit 679221-1 includes a
replacement lock nut and a variety of pins, rings, screws, and springs. If the dies are damaged or worn
excessively, they must be replaced. Parts other than those listed should be replaced by TE Connectivity to
ensure quality and reliability. For customer repair service or to order replacement parts, call 1-800-522-6752, or
fax your purchase order to 717-986-7605, or write to: Customer Service (038-035), Tyco Electronics
Corporation, PO Box 3608, Harrisburg, PA 17105-3608.
10. REVISION SUMMARY
Updated document to corporate requirements
Updated tooling information on last page of document
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