408-35007
Rev D
5
of 7
Visual Inspection
1. Close tool handles until ratchet releases and then allow them to open freely. If they do not open
quickly and fully, the spring is defective and must be replaced. See Section 7, REPLACEMENT AND
REPAIR.
2. Inspect head assembly for worn, cracked, or broken jaws. If damage is evident, return the tool to TE
for evaluation and repair. See Section 7, REPLACEMENT AND REPAIR.
Crimping Die Closure Inspections
1. Each tool is inspected for proper die closure before shipment. However, die closure must be inspected
periodically due to the effects of wear. This inspection requires the use of plug gages conforming to
the dimensions shown in Figure 5.
NOTE
TE Connectivity does not manufacture or sell these gages.
a. To gage die closure, refer to Figure 6 and proceed as follows:
(1) Remove traces of oil or dirt from the crimping chamber and plug gage.
(2) Remove Hold Down.
(3) Close the tool handles until the wire barrel dies are bottomed. Do not apply additional pressure
to the tool handles.
(4) With wire barrel dies bottomed, inspect the wire barrel crimp die closure using the proper plug
gage. Press the spring-loaded locator down and hold gage in alignment with the die closure.
(5) Align the GO element with the wire barrel section of the crimping chamber. Push element
straight into the crimping chamber without using force. The GO element must pass completely
through the crimping chamber (see Figure 6).
(6) Align the NO-GO element and try to insert it straight into the same section of the crimping
chamber. The NO-GO element may start entry, but must not pass completely through the
crimping chamber (see Figure 6).
(7) Insert tool insulation crimping adjustment pin into position No.1.
(8) With crimping dies bottomed, check the insulation barrel section of the crimping chamber as
described in Steps (4) and (5).
(9) Re-install Hold Down.
If the crimping chamber conforms to the gage inspection, the tool is considered dimensionally correct, and
should be lubricated with a THIN coat of any good SAE 20 motor oil. If not, the tool must be returned to TE for
further evaluation and repair. Refer to Section 7, REPLACEMENT AND REPAIR.
For additional information regarding the use of plug gages, refer to Instruction Sheet 408
—
7424
Figure 5
Wire Barrel Crimp Chamber
Insulation Barrel Crimp Chamber
GO
NO-GO
GO
NO-GO
Width (W)
2.362-2.370
[.0930-.0933]
2.461-2.464
[.0969-.0970]
1.067-1.074
[.0420-.0423]
1.471-1.473
[.0579-.0580]
4.39
[.173]
Suggested Plug Gage Design for Insulation
Barrel Section of Crimping Chamber
Suggested Plug Gage Design for Wire
Barrel Section of Crimping Chamber
GO Dim.
GO Dim.
NO-GO Dim.
NO-GO Dim.
50.8 [2] Min Typ
Die Closure
Configuration
6.35 [.250] Min Typ
Die Closure
Configuration
