408-1254 Datasheet, PDF (5/6 Pages) TE Connectivity Ltd – Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.

408-1254
SUGGESTED PLUG GAGE DESIGN - WIRE BARREL CRIMP
Die Closure
"B"
9.52 [.375] Min. Typ. NO-GO Dim.
Configuration
"A" Dim.
"R"
Typ.
"B"
GO Dim.
25.4 [1.00] Min. Typ.
TOOL
DIE CLOSURE
DIM’s “A”{
GO
NO-
GO
GAGE MEMBER}
DIM’s “B”
GO
NO-GO
RADIUS
“R”
69339
3.200 3.353 3.200-3.208 3.350-3.353
[.1260] [.1320] [.1260-.1263] [.1319-.1320]
3.51
[.138]
69354-1
2.540
[.1000]
2.692
[.1060]
2.540-2.548
[.1000-.1003]
2.690-2.692
[.1059-.1060]
3.18
[.125]
69355
2.540 2.692 2.540-2.548 2.690-2.692
[.1000] [.1060] [.1000-.1003] [.1059-.1060]
3.18
[.125]
{Die closure dimensions apply when dies are
bottomed but nut under pressure. }Material-Tool Steel
Figure 7
1. Clean oil or dirt from the die closure and plug
gage members.
2. Close handles of tool until dies are bottomed.
Do NOT apply additional pressure to tool handles.
see Figure 8A.
3. With dies bottomed, inspect the die closure
using the proper plug gage.
4. Hold gage in straight alignment with the die
closure and carefully try to insert, without forcing,
the GO member. See Figure 8, Detail A. The GO
member must pass completely through the die
closure.
5. Try to insert the NO-GO member. The NO-GO
member may enter partially, but must not pass
completely through the die closure.
INSPECTION OF WIRE BARREL CRIMPING DIES
Dies Bottom Here in Flag
Terminal Crimping Tool
"GO" Member Must Pass Completely
Through the Die Closure
Dies Bottomed, but
Not Under Pressure
"NO-GO" Member May Enter
Partially, but Must Not Pass
Completely Through the Die Closure
6. If the die closure meets the GO/NO-GO gage
conditions, the die closure may be considered
dimensionally correct.
7. If you find that the die closure does not conform
with the GO/NO-GO gage conditions, contact your
local TE Representative.
4.5. CERTI-CRIMP Hand Crimping Tool Ratchet Control
Inspection
The CERTI-CRIMP hand crimping tool ratchet control
feature on hand tools should be checked to make
certain that the ratchet does not release prematurely
allowing dies to open before they have fully bottomed.
To check the ratchet feature:
1. Thoroughly clean the bottoming surfaces of the
dies.
2. Make a test crimp using a properly stripped
No. 8 AWG wire and a terminal. When this crimp is
made, squeeze handles until the ratchet is free,
however, DO NOT RELAX PRESSURE ON TOOL
HANDLES.
3. Bottoming is satisfactory if bottoming surfaces of
the wire barrel crimp dies make contact with each
other or if the clearance between the bottoming
surfaces is 0.03 mm [.001 in.] or less.
4. If the 0.03 mm [.001 in.] shim stock can be
inserted completely between the bottoming
surfaces of the wire barrel crimp dies, the dies are
considered as not bottoming. Contact your local TE
Representative.
4.6. Replacement Parts
The parts listed in Figure 9 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
Representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 717-986-7605, or
write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Tools may be returned to TE for evaluation and repair.
For tool repair service, contact a TE Representative at
1-800-526-5136.
5. REVISION SUMMARY
• Updated document to corporate requirements
• Changed information in Figure 9
Figure 8
Rev D
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