408-9938
4 of 5
Rev D
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. TE 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 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.
Figure 4
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,
RATCHET (Crimp Height) ADJUSTMENT.
7. RATCHET (Crimp Height) ADJUSTMENT (Figure 5)
1. Remove the lockscrew from the ratchet
adjustment wheel.
2. Using 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.
Figure 5
8. 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 the tool. When not in use, keep tool
handles closed to prevent objects from becoming
lodged in the 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
Customer-replaceable parts are shown in Figure 1.
Available separately, PRO-CRIMPER III Hand
Crimping 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
11. REVISION SUMMARY
Revisions to this instruction sheet include:
•Updated document to corporate requirements
•Corrected tooling information in Section 1,
INTRODUCTION
WIRE SIZE
AWG (Max)
CRIMP SECTION
(Wire Size
Marking)
CRIMP HEIGHT
DIMENSION “A”
(±0.05 [±.002])
24 26-24 0.69 [.027]
18 22 0.79 [.031]
Position Point
on Center of
Wire Barrel
Opposite
Modified Anvil
“A”
Screwdriver
Lockscrew
Ratchet Adjustment
Wheel
