408-9227 Datasheet, PDF (2/4 Pages) TE Connectivity Ltd – Application and Maintenance for Crimping Die Assemblies

408-9227
4. CRIMPING PROCEDURE
Refer to Figure 2 and select a terminal for the wire of
the specified size. Strip the wire to the length
indicated, taking care not to cut or nick the wire
strands. Make sure the die assembly is compatible
with the terminal being used.
Position the terminal in the die assembly as instructed
in 408-8092 and follow the specific instructions for
crimping .187 Series Ultra-Fast Plus Terminals.
5. MAINTENANCE AND INSPECTION
5.1. Maintenance
1. Remove dust, moisture 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 that all surfaces are protected with
a thin coat of any good SAE No. 20 motor oil. Do not
oil excessively.
3. When dies are not in use, store in a clean, 
dry area.
5.2. Periodic Inspection
Regular inspections should be performed with a
record of inspections remaining with the dies and/or
supervisory personnel responsible for them. 
TE Connectivity recommends one inspection per
month; however, amount of use, working conditions,
operator training and skill, and established company
standards should determine frequency of inspection.
The inspection should be performed in the following
sequence:
A. 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 and secured.
Refer to Section 6, REPLACEMENT AND REPAIR,
if replacements are necessary.
3. Check all bearing surfaces for wear. Replace
worn components.
4. Inspect the crimping chamber for flattened,
chipped, cracked, worn, or broken areas. If damage
is evident, the dies must be repaired before
returning them to service. See Section 6,
REPLACEMENT AND REPAIR.
B. Gaging the Crimping Chamber
This inspection requires the use of a plug gage
conforming to the dimensions in Figure 3. TE does not
manufacture or market these gages. To gage the
crimping chamber, proceed as follows:
1. Remove traces of oil or dirt from crimping
chamber and plug gage.
2. Mate the dies until it is evident that the dies have
bottomed, then HOLD in this position. Do NOT force
the dies beyond initial contact.
3. Align the GO element with the crimping chamber.
Push element straight into the crimping chamber
without using force. The GO element must pass
completely through. Refer to Figure 3.
NOTE
i
Insert INSULATION plug gage in the crimping
chamber from the FRONT side of the die assembly
and insert WIRE BARREL plug gage in the BACK
side of the die assembly.
4. Now align the NO-GO element and try to insert it
straight into the same crimping chamber. The NO-
GO element may start entry but must not pass
completely through as shown in Figure 3.
If the crimping chamber conforms to the gage
inspection, the die assembly is considered
dimensionally correct and should be lubricated with a
THIN coat of any good SAE No. 20 motor oil. If not,
the die assembly must be repaired before returning it
to service. See Section 6, REPLACEMENT AND
REPAIR.
For additional information concerning the use of the
plug gage, refer to instruction sheet 408-7424.
6. REPLACEMENT AND REPAIR
Replacement parts or recommended spares are listed
in Figure 4. The recommended spares should be
stocked for immediate replacement. Order
replacement parts through your TE representative or
call 1-800-526-5142, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
7. REVISION SUMMARY
Since the previous version of this document, the
following changes were made:
• Updated document to corporate requirements.
Rev C
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