408-8705

Crimping Die Assemblies

3 of 6

Rev A

Tyco Electronics Corporation

3.2. Insulation Crimp Adjustment

This adjustment is made to both stationary and

moving dies after they have been placed in crimping

head.

Crimping Dies have four socket head cap screws

and two pin-keys for insulation crimp adjustment.

1. The dies have three insulation crimp positions.

The adjustment is made by moving a pin–key (see

Figure 1). When the pin–key is pushed all the way

in, the insulation crimping section of the die is in

the loose position; when the pin–key is halfway

out, the insulation crimping section of the die is in

the medium position; when the pin–key is all the

way out, the insulation crimping section of the die

is in the tight position.

2. To adjust the insulation crimp, loosen socket

head cap screws and push pin–key all the way in

so that insulation crimp section of the die is in the

loose position.

3. Press and hold insulation die down against the

pin–key. This will prevent the spring–loaded

pin–key from popping back.

4. Tighten socket head cap screws.

Make certain insulation crimping sections of

moving and stationary dies are both adjusted to

the same position.

5. Perform a test crimp (refer to Paragraph 3.1).

AMPLI-BOND and AMPOWER terminals provide

a grip" on wire insulation. PLASTI-GRIP

terminals provide only a support" for the wire.

6. Remove crimped terminal from dies and visually

inspect the insulation crimp portion of terminal. The

insulation crimp should “

grip” wire insulation (when

using AMPLI–BOND or AMPOWER terminals) or

provide “

support” for wire insulation (when using

PLASTI–GRIP terminals).

7. If the insulation crimp does not grip or support

wire insulation as described in step 6, loosen

socket head cap screws and set the pin–keys in

the medium position. Then follow Steps 3 and 4.

8. Make another test crimp over previously

crimped terminal.

9. Remove crimped terminal from dies and visually

inspect insulation crimp.

10. Repeat adjustment as necessary until desired

insulation crimp is obtained. Do NOT use a tighter

setting than required.

11. Refer to Paragraph 3.4 and Figure 4 for crimp

inspection procedure.

3.3. Color Code

Terminals and dies are color coded as listed and

shown in Figure 1. The dies have the terminal size

stamped in the wire barrel crimp sections of both the

moving and stationary dies. When crimped, the wire

size will appear on both sides of the terminal wire

barrel. The wire size appearing on the crimped wire

barrel should always agree with the wire size stamped

on the terminal tongue.

3.4. Crimp Inspection

Inspect crimped terminals by checking the features

described in Figure 4.

AMPLI-BOND terminals are shown in Figure 4.

Inspection procedure is the same for AMPOWER

and PLASTI-GRIP terminals.

Use only the terminals that meet the conditions

shown in the “ACCEPT” column. “REJECT” terminals

can be avoided through careful use of instructions in

Paragraphs 3.1 and 3.2, and by performing regular

die maintenance described in Section 4.

4. MAINTENANCE/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 the

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:

4.1. Cleaning

Do not allow deposits of dirt, grease, or foreign matter

to accumulate in the die closure area, or on the

bottoming surfaces of the dies. These deposits may

prevent the dies from bottoming fully and may also

cause excessive wear in the die closure surfaces,

thereby affecting the quality of the crimp. The dies

should be wiped clean frequently with a clean cloth.

4.2. Visual Inspection

Visually inspect the die closure surfaces for flattened,

broken, pitted, or chipped conditions. Although dies

may gage within permissible limits, worn or damaged

die closure surfaces are objectionable and can affect

the quality of the crimp. Examples of possible

damaged die surfaces are shown in Figure 5.

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