408- 2353

Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts

9

of 12

Rev B

Tyco Electronics Corporation

5. MAINTENANCE/INSPECTION

AVOID PERSONAL INJURY; exercise extreme

caution when using power unit. Avoid depressing

foot switch or trigger control when installing or

removing die assemblies.

Customer--replaceable parts are listed in Figure 9.

A complete inventory should be stocked and

controlled to prevent lost time when replacement of

parts is necessary.

Crimping Die Assemblies are inspected before

shipment. Tyco Electronics recommends that the die

assembly be inspected immediately upon arrival at

your facility to ensure that it has not been damaged

during shipment.

5.1. Daily Maintenance

It is recommended that each operator of the tool be

made aware of -- and responsible for -- the following

three steps of daily 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 the dies are protected with a THIN

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

EXCESSIVELY.

Wipe excess oil from tool, particularly from

crimping area. Oil transferred from the crimping

area onto certain terminations may affect the

electrical characteristics of an application.

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

store the tool in a clean, dry area.

5.2. Periodic Inspection

Tyco Electronics recommends that a maintenance

and inspection program be performed periodically to

ensure dependable and uniform terminations. Though

recommendations call for at least one inspection a

month, frequency of inspection depends on:

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

dies.

2. The presence of abnormal amounts of dust and

dirt.

3. The degree of operator skill.

4. Your own established standards.

A. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the die assembly in a suitable

commercial degreaser that will not affect paint or

plastic material.

2. Inspect the crimp area for flattened, chipped,

cracked, worn, or broken areas. If damage is

evident, the dies must be replaced or repaired.

Examples of possible damaged die closure

surfaces are shown in Figure 6. If desired, you

may return them to Tyco Electronics for evaluation

and repair (see Section 6, REPAIR).

Figure 6

Pitted

Broken Corner

B. Gaging the Crimping Chamber

This inspection requires the use of a plug gage

conforming to the diameters provided in Figure 7.

Tyco Electronics does not manufacture or market

these gages. The following procedure is

recommended for inspecting the die closures.

1. Clean oil or dirt from the die closure areas, and

plug gage elements.

2. Assemble and adjust dies to meet the “gage

dimension” indicated in Figure 8, Detail A.

3. With dies positioned at the “gage dimension,”

inspect the bar crimp closure using the proper plug

gage. 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 8,

Detail A.

4. 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 through, as shown in Figure 8,

Detail A.

5. With dies positioned at “gage dimension,” check

the right and left rectangular crimp closures using

the proper plug gage in the same manner as Steps

4 and 5; see Figure 8, Detail B.

DANGER

NOTE

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