408-7594
3 of 4
Rev B
Make sure all pivot points and bearing surfaces are
protected with a thin coat of any good SAE 20 motor
oil. Do NOT oil excessively. When the tool is not in
use, keep the handles closed to prevent objects from
becoming lodged between the dies, and store the tool
in a clean, dry area.
5.2. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the tool and/or be supplied to the
supervisory personnel responsible for the tool. Though
recommendations call for at least one inspection a
month, the inspection frequency should be based on
the amount of use, ambient working conditions,
operator training and skill, and established company
standards. These inspections should be performed in
the following sequence:
A. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the tool (handles partially closed) into a
suitable degreaser that will not affect paint or plastic
material.
2. Make certain all retaining pins are in place and
a
re secured with the proper retaining rings. If
replacements are necessary, refer to Figure 5.
3. Close the tool handles until the ratchet releases,
a
nd then allow the handles to open freely. If they do
not open quickly and fully, then the spring is
defective and must be replaced (see Section 6,
REPLACEMENT AND REPAIR).
4. Inspect the head assembly, with special
e
mphasis on checking for worn, cracked, or broken
crimping dies. If damage to any part of the head is
evident, return the tool for evaluation and repair
(see Section 6, REPLACEMENT AND REPAIR).
B. 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 market crimp height comparators.
Refer to Instruction Sheet 408-7424 for detailed
information on obtaining and using a crimp height
comparator.
Proceed as follows:
1. Refer to the chart in Figure 4 and select a contact
and a wire (maximum size) for each crimp section.
2. Refer to Section
3, 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 chart,
the tool is considered dimensionally correct. If not,
return the tool for evaluation and repair (refer to
Section 6, REPLACEMENT AND REPAIR).
Position Point on
Center of Wire
Barrel Opposite
Seam
Modified
Anvil
“A”
±0.05
[±.002]
CONTACT
NUMBER
(LP)
WIRE SIZE
AW
G (Max)
CRIMP SECT
(Wire Size
Marking)
CRIMP
HE
IGHT DIM.
“A”
87026
870
27
102103
102104
20 22-20 0.84 [.033]
18 18 1.07 [.042]
Figure 4
C. Ratchet Inspection
Obtain a 0.025 [.001] shim that is suitable for checking
the clearance between the bottoming surfaces of the
crimping dies. Proceed as follows:
1. Select a contact and maximum size wire for the
ha
nd tool.
2. Position the contact and wire between the
crim
ping dies, as described in Section 3,
CRIMPING PROCEDURE.
3. Holding the wire in place, squeeze the tool
ha
ndles together until the ratchet releases. Hold the
handles in this position, maintaining just enough
tension to keep the dies closed.
4. Check the clearance between the bottoming
sur
faces of the crimping dies. If the clearance is
0.025 [.001] or less, the ratchet is satisfactory. If the
clearance exceeds 0.025 [.001], the ratchet is out of
adjustment and must be repaired.
