408-2823
4
of 6
Rev Z
4. When the tool is not in use, keep handles closed
to prevent objects from becoming lodged in the
crimping dies. Store the tool in a clean, dry area.
5.2. Periodic Inspection
A. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with SAE 20 motor oil as follows:
— Tool used in daily production-lubricate daily
— Tool used daily (occasional)-lubricate weekly
— Tool used weekly-lubricate monthly
Wipe excess oil from tool, particularly from crimping
area. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
B. 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 6, REPLACEMENT AND
REPAIR.
2. Inspect crimping area for worn, cracked, or
broken dies. If damage is evident, return the tool for
evaluation and repair. See Section 6,
REPLACEMENT AND REPAIR.
C. Ratchet Inspection
The ratchet feature on these hand tools should be
checked to ensure that the ratchet does not release
prematurely, allowing the dies to open before they
have fully bottomed.
1. Squeeze the tool handles together, and count the
number of ratchet stops. Five stops, including the
release position, should be indicated by the
movement of the ratchet pawl and the clicking
sound associated with its movement. Refer to
Figure 1.
2. If fewer positions are indicated, the ratchet pawl
and ratchet handle must be replaced. Refer to
Section 6, REPLACEMENT AND REPAIR.
3. If dies do not bottom after 5 ratchet stops, return
tool for repair. Refer to Section 6, REPLACEMENT
AND REPAIR.
When the tool passes the ratchet inspection, lubricate
it with a THIN coat of any good SAE 20 motor oil.
D. Gaging the Crimping Chamber
(Figure 5)
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. In order to properly gage this tool, a terminal must
be crimped in the crimping chamber being
inspected. In place of a terminal, a soft material
such as brass or solder may be used to seat the
tooling.
Figure 5
3. Close the tool handles until the crimping dies
have bottomed; then hold in this position. DO NOT
force the dies beyond initial contact.
4. Hold locator assembly away from crimping dies.
Carefully insert GO element into the corresponding
crimping chamber; do not force it. The GO element
must pass completely through the crimping
chamber.
5. In the same manner, try to insert the NO-GO
element into the same crimping chamber. The NO-
GO element may start entry, but must not pass
completely through the crimping chamber. See
Figure 5.
CRIMPING
CHAMBER
COLOR
CODE
GAGE ELEMENT DIAMETER
“W”
(Width)
Max
GO
NO-GO
Red
1.981-1.988
[.0780-.0783]
2.181-2.184
[.0859-.0860]
4.69 [.185]
Blue/Green
2.336-2.344
[.0920-.0923]
2.537-2.540
[.0999-.1000]
5.33 [.210]
Yellow/Black
3.251-3.258
[.1280-.1283]
3.451-3.454
[.1359-.1360]
6.85 [.270]
Suggested Plug Gage Design
for Wire Crimping Chamber
Inspection of Wire Crimping Chamber
GO element must pass
completely through the wire
crimping chamber only.
NO-GO element may enter
partially, but must not pass
completely through the wire
crimping chamber.