408-8704

Crimping Die Assemblies

5 of 7

Rev A

Tyco Electronics Corporation

Figure 7

4

WireSize

Stamped

Here

ACCEPT

4

4

2

4

4

2

3

6

3

5

2

5

1

3

4

REJECT

8

4

1

4

2

5

10

3

WireSize

Stamped

Here 4

9

9

4

5

6

10

8

4

2

10

4

7

WireSize

Stamped

Here

WireSize

Stamped

Here

WireSize

Stamped

Here

1

2

3

4

5

6

End of wire conductor is flush with or extends beyond edge of

terminal wire barrel a maximum of 1.60 mm [.063 in.].

Wire fully inserted.

Crimp centered on wire barrel.

Wiresizeis thesameas wiresizestamped on terminal

tongue, splice body, and wire barrel.

Proper color code, wire size, and tooling combination used.

Wireconductors butted against wirestop, or flush with or

extended slightly beyond edge of splice wire barrel.

1

2

3

4

5

6

End of wire conductor not flush with or extending slightly

beyond end of terminal wire barrel.

Wire not inserted fully or wrong strip length used.

Crimp not centered on terminal wire barrel. Terminal wire

barrel was not butted against locator when crimped.

Wiresizenot thesameas wiresizestamped on terminal

tongue, splice body, and wire barrel.

Wrong color code, wire size, and tooling combination used.

End of wireconductor not visible. Conductor did not butt

against wire stop, or was not flush with or extended slightly

beyond splicewirebarrel.

7

8

9

10

Crimp not centered on splice wire barrel. Edge of window

indent did not butt against locator when crimped.

Nicked or missing wire strands.

Splice was reversed in die (locator was not oriented with

window indent) when crimped.

Excessive flash" or extruded wire insulation (die was either

damaged or incompatible when crimped).

4. Inspect the crimp area for flattened, chipped,

cracked, worn, or broken areas. If damage is

evident, the dies must be repaired before returning

them to service (see Section 7, REPLACEMENT

AND REPAIR).

6.3. Gaging the Crimping Chamber

The die closure inspection is accomplished using plug

gages. A suggested gage design and the GO and

NO–GO diameters of the plug gage elements are

shown in Figure 8. The following procedure is

recommended for inspecting the die closures.