408-1535

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Rev S

4. Perform a test crimp as described in Section 3,

Step 6. Remove the crimped terminal or splice and

check the insulation support. Bend the wire back

and forth once. The insulation barrel sleeve should

retain grip on the wire insulation. If the wire pulls

out, move the insulation crimping adjustment pins to

the next tighter position (Position 2) and proceed to

Step 5. If the wire does not pull out, the pins are

properly adjusted and the tool is ready for crimping.

5. Perform another test crimp as described in

Step 4. Adjust pins, as necessary, until the desired

insulation grip is obtained. Do not use a tighter

setting than is required.

The insulation crimping adjustment pins must be

located in the same adjustment position.

5. MAINTENANCE AND INSPECTION PROCEDURE

It is recommended that a maintenance and inspection

program be performed periodically to ensure

dependable and uniform terminations. Frequency of

inspection should be adjusted to suit your

requirements through experience and depends on:

1. The care, amount of use, and handling of the

hand tool.

2. The presence of abnormal amounts of dust and

dirt.

3. The degree of operator skill.

4. Your own established standards.

The hand tool is inspected and calibrated before being

shipped; however, it is recommended that the tool be

inspected immediately upon arrival to ensure that the

tool has not been damaged during shipment.

5.1. Daily Maintenance

1. The hand tool should be immersed (handles

partially closed) in a reliable commercial degreasing

compound to remove accumulated dirt, grease, and

foreign matter. When degreasing compound is not

available, tool may be wiped clean with a soft, lint-

free cloth. Do NOT use hard or abrasive objects that

could damage the tool.

2. Make certain that the retaining pins are in place

and that they are secured with retaining rings.

3. All pins, pivot points, and bearing surfaces should

be protected with a thin coat of any good SAE 20

motor oil. Do not oil excessively.

4. When the tool is not in use, keep handles closed

to prevent objects from becoming lodged in the

crimping jaws. Store the tool in a clean, dry area.

5.2. 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.

5.3. 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. nspect head assembly for worn, cracked, or

broken jaws. If damage is evident, return the tool for

evaluation and repair. Refer to Section 6,

REPLACEMENT AND REPAIR.

5.4. Gaging the Crimping Chamber

This inspection requires the use of plug gages

conforming to the dimensions provided in Figure 7. TE

does not manufacture or market these gages.

To gage the crimping chamber, proceed as follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gages.

2. Remove locator assembly.

DO NOT lose spring in locator assembly.

3. Close the tool handles until the crimping jaws

have bottomed. Do NOT force jaws beyond initial

contact.

4. 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 8.

5. 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 8.

6. Re-install locator assembly.

7. Insert tool insulation crimping adjustment pins

into Position 1.

8. With crimping jaws bottomed, check the

insulation barrel section of the crimping chamber as

described in Steps 4 and 5.

NOTE

i

CAUTION

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