790163-1 TE Connectivity, 790163-1 Datasheet - Page 3

• Manufacturer Part Number: 790163-1
• Description: HAND TOOL ASSEMBLY AND DIE ASSEMBLY
• Manufacturer: TE Connectivity
• Type: Hand Toolr

Specifications of 790163-1

• Rohs Compliant: NA
• Lead Free Status / RoHS Status: RoHS Not Applicable

Rev M
Insulation
Stuffer
Modular Plug
(Ref)
Housing Support
3. While holding the assembly, carefully close the
tool handles until the ratchet releases, then allow
the handles to open FULLY.
4. Remove the modular plug from the tool, and
make sure that the crimp requirements are met
according to the applicable application specification
(refer to first paragraph of Section 4).
If necessary, adjust the tool ratchet according to
Paragraph 5.1 to obtain the proper crimp height.
NOTE
NOTE
i
i
Wire Stuffer
This tool terminates 3 areas of the modular plug.
For proper alignment, make sure to apply forward
pressure on the cable while closing the tool
handles.
Crimp Height Gage 904170-1 is to be used as a
quick verification of acceptable crimp height as
Checking Crimp Height
Figure 3
Figure 4
Modular Plug Bottomed
in Crimping Chamber
Crimp Height Gage
(Ref)
5. ADJUSTMENTS
5.1. Ratchet Adjustment
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. If the crimp is not acceptable,
adjust the ratchet as follows:
5.2. Wire Stuffer Adjustment
If the wire stuffer is not assembled onto the insulation
stuffer or if correct alignment of these two parts is
unsure, proceed with the following:
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
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. If the crimp is acceptable,
the adjustment setting is correct. If the crimp is
unacceptable, continue to adjust the ratchet, and
again measure a sample crimp. If a proper crimp
cannot be obtained, the tool or die assembly must
be replaced. Refer to Section 7.
1. Install the wire stuffer onto the insulation stuffer
using the 4-40 UNC.621 in. socket head cap screw
included with the die assembly. Refer to Figure 2.
2. Close the tool handles until the ratchet releases,
then allow the handles to open FULLY. Insert a
modular plug (without cable) into the crimping
chamber.
3. Close the tool handles, and hold.
4. Insert a key into the socket head cap screw
(retaining the wire stuffer), and tighten the screw.
NOTE
NOTE
i
i
shown in Figure 4. Refer to Instruction Sheet 408-
4389 for instructions on using the gage.
The tool is set at the No. 7 ratchet setting at the
factory. This setting assures the proper crimp
height for solid wire and accounts for the maximum
tolerance in the tooling. You can readjust your tool
to a lower setting, (No. 4, minimum), as long as
you achieve the proper insertion depth, 6.02 ± .13
[.237 ± .005). See the applicable application
specification
DO NOT tighten the screw. If the screw is tight,
loosen it.
(Figure 5)
408-8738
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