408- 1634

Die Assemblies 45218, 45221, 69303- 2, and 69820

3

of 6

Rev C

Tyco Electronics Corporation

Setting 1—Tight

Turn both insulation adjustment spacers until the “1” (stamped on

the die) is visible at the beveled corner of the spacers. When

installed into the tool, the L--shaped edge of the spacers will fit

between the die and the tool.

Setting 2—Medium

Turn the insulation adjustment spacer closest to the die until the

“2” (stamped on the die) is visible at the beveled corner of the

spacer. When installed into the tool, the L--shaped edge of the

spacer will fit between the die and the tool.

Setting 3—Loose

Turn both insulation adjustment spacers until the “3” (stamped on

the die) is visible at the beveled corner of the spacers. The

L--shaped edge of the spacer will fit into the notch in the side of

the die.

Figure 5

Setting 3

Shown

Insulation

Adjustment Spacers

Screw Loosened

Die Assembly 69820 Shown

3. Tighten the die screw. Install die into tool.

4. Perform a test crimp following the steps in

Section 4, and inspect the splice insulation. If the

crimp cuts into, or otherwise damages, the

insulation, start with Step 1 and set the insulation

crimp adjustment to the next setting (Setting 2, as

described in Figure 5). Perform another test crimp.

If the crimp does not meet requirements, set the

adjustment to Setting 3. If the crimp meets

requirements, the adjustment is properly set.

6. MAINTENANCE AND INSPECTION

6.1. Daily Maintenance

It is recommended that each operator of the die

assembly be made aware of, and responsible for, the

following steps of daily maintenance:

1. Remove all foreign particles from the dies with a

clean, soft brush, or a clean, soft, lint--free cloth.

Do not use objects that could damage the dies.

SAE is a trademark of SAE International Corporation.

2. Make sure that the proper screws and retaining

rings are in place and are secured. Check die

alignment and tighten screws (twice daily is

recommended for production use).

3. Make certain that the dies are protected with a

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

oil excessively.

4. When dies are not in use, mate them and store

them in a clean, dry area.

Regular inspections should be performed by quality

control personnel with a record of scheduled

inspection remaining with the die assembly or

supplied to personnel responsible for them. Though

recommendations call for at least one inspection per

month, inspection frequency should be based upon

amount of use, working conditions, operator training

and skill, and established company standards. The

inspections should be performed in the following

sequence.

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 that screws, retaining rings, and die

components are in place.

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.

6.3. Gaging the Crimping Chamber

This inspection requires the use of plug gages

conforming to the dimensions provided in Figure 6.

To gage the crimping chamber, proceed as follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gage.

2. For pneumatic tools, reduce air supply pressure

on tool to between 103 and 138 kPa [15 and

20 psi]. Actuate tool until dies bottom. For manual

tools, close handles until dies bottom. DO NOT

force beyond initial contact.

3. Insert GO element into the crimping chamber;

but do not force it. The GO element must pass

completely through the crimping chamber. See

Figure 7.