408- 7114
3
of 4
Rev
B
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
are secured with the proper retaining rings. If
replacements are necessary, refer to Figure 5.
3. Close the tool handles until the ratchet releases,
and 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 5,
REPLACEMENT AND REPAIR).
4. Inspect the tool, with special emphasis on
checking for worn, cracked, or broken crimping
jaws. If damage to any part of the head is evident,
return the tool for evaluation and repair (see
Section 5, REPLACEMENT AND REPAIR).
B. Crimp Height Inspection
This inspection requires the use of a micrometer, with
a modified anvil, as shown in Figure 4. The Crimp
Height Comparator RS--1019--5LP is recommended
and is available from:
Shearer Industrial Supply Co.
20 North Penn Street
York, PA 17401--1014
VALCO
1410 Stonewood Drive
Bethlehem, PA 18017--3527
or
Proceed as follows:
1. Refer to the chart in Figure 4 and select a
terminal and a wire (maximum size) for the hand
tool.
Position Point on
Center of Wire
Barrel Opposite
Seam
Modified
Anvil
“A”
+0.05 [+.002]
TERMINAL
NUMBER
WIRE SIZE
AWG (Max.)
CRIMP HEIGHT
DIM. “A”
60560 61403
60561 60751
60578
20
0.81 [.032]
Figure 4
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the terminal 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 5, REPLACEMENT AND REPAIR).
For additional information concerning the use of the
crimp height comparator, refer to Instruction Sheet
408--7424.
C. Ratchet Inspection
Obtain a 0.025 [.001] shim that is suitable for
checking the clearance between the bottoming
surfaces of the crimping jaws. Proceed as follows:
1. Select a terminal and
maximum
size wire for the
hand tool.
2. Position the terminal and wire between the
crimping jaws, as described in Section 3,
CRIMPING PROCEDURE.
3. Holding the wire in place, squeeze the tool
handles together until the ratchet releases. Hold
the handles in this position, maintaining just
enough tension to keep the jaws closed.
4. Check the clearance between the bottoming
surfaces of the crimping jaws. 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.
If the tool conforms to these inspection procedures,
lubricate it with a thin coat of any good SAE 20 motor
oil and return it to service.
5. REPLACEMENT AND REPAIR
The parts listed in Figure 5 are customer--
replaceable. A complete inventory can be stocked
and controlled to prevent lost time when replacement
of parts is necessary. Order replacement parts
through your TE Connectivity 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 (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
Tools may be returned for evaluation and repair. For
tool repair service, contact a representative at
1--800--526--5136.
6. REVISION SUMMARY
Since the previous version of this document, the
following changes were made:
:
Updated document to corporate requirements.
