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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.
408-32084
The die set consists of an indenter (upper die) and an anvil (lower die). The tool frame holds a die assembly
with two crimping chambers. See Figure 1. Die retaining screws are used to secure the dies in the tool frame.
The tool features a ratchet and an adjustment wheel with a range of settings. The ratchet ensures that the tool
has completed the cycle and will not release until the handles have been FULLY closed, unless the emergency
ratchet release is rotated to manually release the ratchet. The adjustment wheel controls the amount of handle
pressure exerted on the dies during the crimping procedure.
CAUTION
The dies bottom before the ratchet releases. This feature ensures maximum tensile performance of the crimp. DO NOT re-
adjust the ratchet.
3. INSTALLATION AND REMOVAL OF DIE SET AND LOCATOR ASSEMBLY
(Figure 1)
1. Open the tool handles and remove the two die retaining screws from the tool jaws.
2. Place the wire anvil so that the chamfered side and the marked surfaces face outward, when mounted
in the moving jaw of the tool frame.
3. Insert the die retaining screw through the jaw and through the anvil die, and tighten the screw just
enough to hold the die in place. Do not tighten the screw completely at this time.
4. Place the wire crimper so that the chamfered side and the marked surface face outward, when
mounted in the stationary jaw of the tool frame.
5. Insert the die retaining screw through the jaw and through the crimper die, and tighten the screw just
enough to hold the die in place. Do not tighten the screw completely at this time.
6. Carefully close the tool handles, making sure that the anvil and crimper align properly. Continue
closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold the anvil and
crimper in place, then tighten both die retaining screws.
7. Place the nut onto the end of the long screw and tighten the nut enough to hold the locator assembly
in place.
8. To disassemble, close the tool handles until the ratchet releases, remove the nut, locator assembly,
the four die retaining screws, and slide the anvil and crimper out of the tool jaws.
NOTE
The ratchet has detents with audible “clicks” as the handles are closed. The ratchet releases on the sixth “click”.
4. CRIMPING PROCEDURE
NOTE
The tool is provided with a crimp adjustment feature. Initially, the crimp height should be verified as specified in Figure 3. Refer
to Section 5, Crimp Height Inspection, and Section 6, Crimp Height Adjustment, to verify crimp height before using the tool to
crimp desired contacts and wire sizes.
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.
Locator
Back of Tool
(Wire Side)
Insert
Wire
Here
Figure 2
Rev B
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408-32084
Select an applicable contact and identify the appropriate crimp section according to the wire size markings on
the tool. Refer to Figure 2 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 mating end, insert the contact through the front of the tool and into the
appropriate crimp section.
Position Point on
Center of Wire
Barrel Opposite
Seam
Modified Anvil
WIRE SIZE MAX
mm
2
[AWG]
1.27 [16]
2217208-[ ]
0.89 [18]
0.56 [20]
0.56 [20]
2211267-[ ]
2 X 0.56 [2 X 20]
0.34 [22]
Figure 3
CRIMP SECTION
(WIRE SIZE MARKINGS)
16
18
20
20
2 X 20
22
CRIMP HEIGHT
DIMENSION “A”
1.35 ±0.06 [.0531 ±.0024]
1.19 ±0.06 [.0468 ±.0024]
1.06 ±0.06 [.0417 ±.0024]
1.050 ±0.03 [.041 ±.001]
1.28 +0.04/-0.08 [.050 +.0015/-.0030]
0.98 +0.03/-0.06 [.038 +.001/-.002]
“A”
TOOLING
3. Position the contact so that the open “U” of the wire barrel faces the top of the tool. Place the contact
up into the nest so that the wire barrel is against the locator.
CAUTION
Make sure that both sides of the wire barrel are started evenly into the crimping section. Do not attempt to crimp an improperly
positioned contact.
5. 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 Connectivity does not manufacture or market crimp-height comparators.
Detailed information on obtaining and using crimp-height comparators can be found in Instruction Sheet
408-7424.
Proceed as follows:
1. Refer to Figure 1 and select a wire (maximum size) for each crimp section listed.
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 listed in Figure 3. 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 6, RATCHET (Crimp Height) ADJUSTMENT.
CAUTION
Damaged product should not be used. If a damaged contact is evident, it should be replaced. Contacts must not be re-
terminated.
6. RATCHET (CRIMP HEIGHT) ADJUSTMENT
Although the ratchet is preset prior to shipment, it is important to verify the crimp height using a micrometer or
caliper. General use and subsequent wear may cause the tool to go out of adjustment. It is recommended that
crimp height be inspected, and the ratchet be adjusted, if necessary, on a regular basis. Refer to Figure 4, and
proceed as follows:
Rev B
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408-32084
1. If the crimp height is larger than recommended, remove the ratchet wheel adjustment screw and
rotate the adjustment wheel counterclockwise (+) to a higher setting. Reinstall the screw. Repeat as
required.
2. If the crimp height is smaller than recommended, remove the ratchet wheel adjustment screw and
rotate the adjustment wheel clockwise (-) to a lower setting. Reinstall the screw. Repeat as required.
3. If the crimp cannot be made to conform to the recommended crimp height, the tool or die set must be
replaced. See Section 8, REPLACEMENT.
7. MAINTENANCE AND INSPECTION
7.1. Daily 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 tool is not in use, keep the handles closed to prevent objects from becoming lodged in the
dies. Store the tool in a clean, dry area.
4. Remove all lubrication and accumulated film from the dies by immersing the dies in a suitable
commercial degreaser.
Adjustment
Screw
Ratchet Adjustment
Wheel
Figure 4
7.2. Inspection
Close the tool handles until the ratchet releases, and then allow them to quickly open freely. If they do not open
quickly and fully, the spring is defective. See Section 8, REPLACEMENT.
8. REPLACEMENT
Order replacements through your TE 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
9. REVISION SUMMARY
Updated document to corporate requirements
Added part number 2217267-[ ] to document with related information
Rev B
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408-32084
Tooling Compatible with Die Assemblies 2217208-2 and 2217267-2
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