408- 2822

Rev B

4

of 7

5. CRIMP INSPECTION

Inspect crimped terminals and splices by checking the

features described in Figure 3.

Use only the terminals and splices that meet

conditions shown in the “ACCEPT” column.

“REJECT” terminals and splices can be avoided

through careful use of instructions provided in the

machine manual and by performing regular die

maintenance as instructed in Paragraph 6 of this

Instruction Sheet.

6. DIE MAINTENANCE/INSPECTION PROCEDURE

Disconnect power supply from tooling before any

inspection, maintenance, adjustment, or repair.

TE Connectivity recommends that a

maintenance/inspection program be performed

periodically to ensure dependable and uniform

terminations. Frequency of inspection may be

adjusted to suit your requirements through

experience.

Frequency of inspection depends on:

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

dies.

2. Type and size of products being crimped.

3. Skill level of the operator.

4. Presence of abnormal amounts of dust and dirt.

5. Your own established standards.

6.1. Initial Die Inspection

The dies are thoroughly inspected before shipping.

The dies should be inspected immediately upon

arrival at your facility to ensure the dies have not

been damaged during shipment, and that they

conform to Figure 7. If the dies are damaged upon

arrival, retain the shipping container, file a claim with

the carrier, and notify TE immediately.

6.2. Daily Maintenance

It is recommended that each operator of the dies be

made aware of — and responsible for — the following

four steps of daily maintenance.

1. Remove dust, moisture, and other contaminants

from the dies with a clean brush, or a soft, lint--free

cloth. Do NOT use objects that could damage the

dies.

2. Check the die alignment and tighten the die

holding screws regularly.

3. Make certain the dies are protected with a THIN

coat of any good SAE No. 20 motor oil. Do NOT oil

excessively.

4. When the dies are not in use, store them in a

clean, dry area.

6.3. 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:

6.4. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the dies in a suitable commercial

degreaser that will not affect paint or plastic

material.

2. Make sure all die holding screws, retaining

rings, and die components are in place. Refer to

the parts list in Figure 8 if replacements are

necessary.

3. Check all bearing surfaces for wear. Remove

and replace worn components.

4. Inspect the crimp area for flattened, chipped

cracked, worn, or broken areas. Although dies may

gage within permissible limits, worn or damaged

die closure surfaces are objectionable and can

affect the quality of the crimp. See Figure 4. If

damage is evident, the dies must be repaired

before returning them to service (See Paragraph 7,

DIE REPLACEMENT AND REPAIR).

6.5. Die Closure Inspection

Every die set is inspected for proper die closure

dimensions before packaging. However, inspection of

die closure for excessive wear is required periodically.

Die closure inspection is accomplished using plug

gages.

TE neither manufactures nor sells plug gages. A

suggested plug gage design and the GO and NO--GO

dimensions for plug gage elements are given in

Figures 5 and 6. For additional information concerning

the use of a plug gage, refer to Instruction Sheet

408--7424.

Clean oil or dirt from the die closure surfaces,

bottoming surfaces, and plug gage elements.

DANGER