408-8705 Datasheet, PDF (4/6 Pages) Tyco Electronics – This instruction sheet provides information on product application and a maintenance and inspection

Crimping Die Assemblies
408-8705
Accept
1
Crimp Inspection of
4
3
AMPLI-BOND, AMPOWER and
PLASTI-GRIP Terminals
7
1
Reject
6
2
4
5
5
3
2
6
4
4
1
Wire fully inserted.
2
Crimp centered on wire barrel.
3
Correct color code and die combination. (Terminal insulation
color matches color dots on dies.)
4
Wire size being used is same as wire size embossed on
terminal insulation and stamped on terminal tongue.
5
End of conductor is flush with or extends beyond end of
wire barrel of terminal.
6
Insulation barrel is in contact with wire insulation.
(AMPLI-BOND terminals have insulation grip" and
PLASTI-GRIP terminals have insulation support".)
1
Wire not fully inserted.
2
Crimp not centered on wire barrel. (Terminal was not butted
against stop plate. See Figure 4.)
3
Wrong die and terminal color code combination. See Figure 1.
4
Excessive flash or extruded insulation. (Wrong size or damaged
dies.)
5
End of conductor is not flush with or extending beyond end of
wire barrel of terminal.
6
Wire insulation pinched. (Insulation crimp too tight on
AMPLI-BOND terminals.)
7
Nicked or missing conductor strands.
Figure 4
Broken Corner
3. Assemble stationary and moving dies so that
wire barrel dies are bottomed, but not under
pressure. See Figure 8.
Chipped or
Flattened
Edge
Pitted
4. With wire barrel dies bottomed, inspect the wire
barrel crimp die closure using the proper plug
gage. Hold gage in straight alignment with the die
closure and carefully try to insert, without forcing,
the GO element. See Figure 8, Detail A. The GO
element must pass completely through the wire
barrel crimp die closure.
5. Try to insert the NO–GO element. The NO–GO
element may enter partially, but must not pass
completely through the wire barrel die closure.
Figure 5
6. Re–install locator and secure with the two
socket head cap screws.
4.3. Plug Gage Inspection
Every die set is inspected and tested for proper die
closure dimensions before packaging. An inspection
should be performed periodically to check the die
closure for excessive wear. A suggested gage design
and the GO and NO–GO dimensions of the plug gage
elements are shown in Figures 6 and 7. The following
procedure is recommended for inspecting the die set.
1. Clean oil or dirt from the bottoming surfaces, die
closure surfaces, and plug gage elements.
2. Remove two socket head cap screws and
locator from moving die. See Figure 8, Detail A.
This will provide access to the wire barrel dies for
plug gaging.
7. Loosen socket head cap screws from both
stationary and moving insulation dies and move
pin–keys all the way out so that insulation crimping
sections of dies are in the tight position. See
Figure 8, Detail B.
8. Press and hold insulation die down against
pin–key, and tighten the socket head cap screws.
9. With wire barrel dies bottomed, inspect the
insulation crimp die closure using the proper plug
gage in the same manner as steps 3 through 5.
See Figure 8, Detail B.
10. If both wire barrel and insulation die closures
meet the plug gage conditions, the dies are
considered to be dimensionally correct.
4 of 6
Tyco Electronics Corporation
Rev A