408-2281

Crimping Die Assemblies for COPALUM SealedTerminals andSplices

Rev W

6 of 9

Tyco Electronics Corporation

4. CRIMP INSPECTION

A crimp inspection mark is featured on each crimped

terminal or splice. The mark consists of a dimple on

the face of a cylinder which is embossed in the

primary crimp area of the terminal or splice. The

inspection mark must appear as shown in Application

Specification 114–2134.

The inspection mark must appear as indicated in

114–2134, in order to qualify the terminal or splice as

an acceptable termination. The terminal or splice is

unacceptable and should be rejected if the

identification mark is deformed.

If the mark is deformed, refer to Figure 2 to verify

proper wire CMA and terminal and die combination.

Verify that crimping dies fully bottom during crimp

cycle. Also, determine if dies are in proper

configuration by gaging the crimp chamber specified

in Paragraph 5.2.B.

5. MAINTENANCE AND INSPECTION

To avoid personal injury, ALWAYS DISCONNECT

electrical and air supply to power unit before

performing adjustments, inspections, or repairs.

Die assemblies are inspected before shipment. It is

recommended that the die assembly be inspected

immediately upon arrival at your facility to ensure that

it conforms to the dimensions provided in Figure 7,

and that it has not been damaged during shipment.

5.1. Daily Maintenance

It is recommended that each operator of the dies be

made aware of — and responsible for — the following

three steps of daily maintenance.

1. Remove dust, dirt, and other contaminants with

a clean brush, or a soft, lint–free cloth. DO NOT

use objects that could damage the dies.

2. Make certain the dies are protected with a thin

coat of any good SAE 20 motor oil. DO NOT OIL

EXCESSIVELY.

3. When the dies are not in use, mate them and

store in a clean dry area.

5.2. Periodic Inspection

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the dies and/or be supplied to

supervisory personnel responsible for the dies.

Though recommendations call for at least one

inspection a month, the inspection frequency should

be based on the amount of use, ambient working

conditions, operator training and skill, and established

company standards. These inspections should be

performed in the following sequence:

A. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the die assembly in a suitable

commercial degreaser that will not affect the

painted alignment dots.

2. Inspect the crimp area for flattened, chipped,

cracked, worn, or broken areas. If damage is

evident, the dies must be replaced or repaired. If

desired, you may return them for evaluation and

repair (see Section 6, REPLACEMENT AND

REPAIR).

B. Gaging the Crimping Chamber

This inspection requires the use of a plug gage

conforming to the measurements provided in Figure

6. Gages may be purchased from:

Pennoyer–Dodge Company

6634–T San Fernando Road

Glendale, CA 91201

Proceed as follows:

1. Mate the dies until it is evident that they have

bottomed. Hold the dies in this position.

2. Align the GO element of the gage with the

crimping chamber. Push the element straight into

the chamber without using force. The GO element

must pass completely through the crimping

chamber without using force as shown in Figure 6.

3. Align the NO–GO element with the crimping

chamber and try to insert it straight into the

chamber. The NO–GO element may start entry but

must not pass completely through, as shown in

Figure 6.

If the crimping chamber conforms to the gage

inspection, the dies are considered dimensionally

correct and should be lubricated with a thin coat of

any good SAE 20 motor oil. If not, the dies must be

replaced or repaired before returning them to service.

For additional information concerning the use of the

plug gage, refer to Instruction Sheet 408–7424.

DANGER