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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.
408-4345
Nut
Locator
Assembly
Tool Frame
Nut
Chamfer
Terminal Support
Die Retaining Pins
Wire
Crimper
Offset
Wire Anvil
Insulation Anvil
Insulation
Crimper
Chamfer
Figure 2
Retaining Screws
2. DESCRIPTION
(Figures 1 and 2)
The tool features a tool frame with a stationary jaw and handle, a moving jaw, a moving handle, and an
adjustable ratchet that ensures full contact crimping. The tool frame holds a die assembly with three crimping
sections.
The die assembly features a wire anvil, an insulation anvil, a wire crimper, and an insulation crimper.
Attached to the outside of the tool frame is a locator assembly, which contains a locator, a spring retainer, and
a contact support.
Die retaining pins and die retaining screws are used to position and secure the dies in the tool frame. A nut is
used on the long die retaining screw to hold the locator assembly 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 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 short 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 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 long 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.
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.
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B
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408-4345
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 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 the four die retaining pins, and slide the anvils and crimpers out of
the tool jaws.
4. CONTACT SUPPORT ADJUSTMENT
(Figure 3)
NOTE
The contact support is preset prior to shipment, but minor adjustment may be necessary.
1. Make a sample crimp and determine if the contact is straight, bending upward, or bending downward.
2. If adjustment is required, loosen the screw that holds the contact support onto the locator assembly.
NOTE
The ratchet has detents that create audible clicks as the tool handles are closed.
3. Place a contact with wire into the proper nest and close the tool handles until the ratchet reaches the
sixth click, or until the contact support touches the contact.
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 and close the handles until the ratchet releases.
7. Remove and inspect the contact.
8. 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.
Contact
Support
Locator
Back of Tool
(Wire Side)
Adjustment
Screw for
Contact
Support
NOTE:
Not to Scale
Contact
(Typ)
Strip
Length
Terminal
Support
Wire
Locator in
Wire Stop Slot
Wire Seal
Figure 3
Wire Seal
Wire
Inserted
to Stop
5. CRIMPING PROCEDURE
NOTE
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.
Rev
B
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408-4345
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 crimp section according to the wire size markings on the tool. 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 mating end, insert the contact-insulation barrel first-through the front of the
tool and into the appropriate crimp section.
3. Position the contact so that the mating end of the contact is on the locator side of the tool, and so that
the open “U” of the wire and insulation barrels must face the top of the tool. Place the contact up into
the nest so that the movable locator drops into the slot in the contact. Refer to Figure 3. Butt the front
end of the wire barrel against the movable locator.
CAUTION
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. 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.
5. Insert stripped wire (with the wire seal) into contact insulation and wire barrels until it is butted against
the wire stop, as shown in Figure 3.
6. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to
open and remove crimped contact.
NOTE
The crimped contact may stick in the crimping area, but the contact can be easily removed by pushing downward on the top of
the locator (see Figure 3).
7. Check the contact crimp height as described in Section 6, Crimp Height Inspection. If necessary,
adjust the crimp height as described in Section 7, CRIMP HEIGHT ADJUSTMENT.
6. CRIMP HEIGHT INSPECTION
This inspection requires the use of a micrometer with a modified anvil. Tyco Electronics recommends referring
to Instruction Sheet
408-7424
for use on these type of micrometers.
Proceed as follows:
1. Refer to Figure 4 and select a wire (maximum size) for each crimp section listed.
2. Refer to Section 5, 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 ADJUSTMENT.
Position Point on
Center of Wire
Barrel Opposite
Seam
Refer to Table
in Figure 1 for
Crimp Height
Modified Anvil
Figure 4
7. CRIMP HEIGHT ADJUSTMENT
(Figure 5)
1. Remove the lockscrew from the ratchet adjustment wheel.
Rev
B
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408-4345
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. Re-assemble 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.
Screwdriver
Ratchet
Adjustment
Wheel
Lockscrew (Typ)
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 sections 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 AND REPAIR
Customer-replaceable parts are listed in Figure 1. Parts other than those listed should be replaced by TE 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.
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