Crimping Die Assemblies Instruction Sheet 356611-1, 356611-2, and 356612-1 408-4324 AMF for POWERBAND* Contacts 26 JAN00 RevA Contact The contact support prevents the contact from bending during the crimping procedure. on. 3. CRIMPING PROCEDURE Wire Size Marking Install the die assembly in the tooling accerding to the LocatorWire instructions packaged with the tooling. Stop Select wire of specified size and applicable contact. Strip the insulation from the wire to the length indicated in Figure 2. Be careful not to nick or cut the wire strands. Stationary Moving Die Die (Crimper) (Anvil) Proceed as follows: 1. Looking straight into the FRONT of the crimping chamber, insert the contact (wire barrel first) into the BACK of the crimping chamber. Position the contact in the crimper so that the locator/wire stop enters the contact locator slot. See Figure 3. eens 2. Hold the contact in position and close the dies just enough to hold the contact in place without deforming the wire barrel. Figure 7 1. INTRODUCTION Socket Contact AMP* Crimping Die Assemblies 356611-1, 356611-2, Pin Coniact and 3566121 (shown in Figure 1), are used in conjunction with Hand Crimping Tool 69710-1 or AMPOMATOR* CLS IV Lead-Making Machine 217500-[ ] to crimp the POWERBAND contacts listed in Figure 2 onto wire sizes 8 through 14 AWG. For specific information concerning the hand tool, Strip refer to Instruction Sheet 408-2095; and for the 7 power unit, refer to Customer Manual 409-5866. Locator Slot Wire Barrel NOTE Dimensions on this sheet are in millimeters {with inches in brackets]. Figures and illustrations are for identification only and are not drawn to scale. Wire Note: Not to Scale 2. DESCRIPTION WIRE CONTACT The die assembly consists of a stationary die SIZE STRIP TYPE BASE PART ASSEMBLY {crimper), a movable die (anvil}, a locatorAvire stop, (AWG) | LENGTH NUMBER= and a contact support. Each die is held in the tooling " by a die holding screw. When mated, the die 8 Pin 213841 356611-1 assembly forms a crimping chamber. 10 6.73-7.49 | Socket 913843 356611-2 The stationary die has chamfered corners and [265-295] Pin 213845 features a wire size marking above the crimping 12-14 356612-1 chamber. The moving die has square corners. Socket 213847 = For contact part numbers net listed, refer to Catalog 82021, or call Product The locator/wire stop positions the contact in the Information at the number listed at the bottom of this page. crimping chamber and aids in locating the wire in the contact. In use, it rests in the contact locator slot. Figure 2 2000 Tyco Electronics Corporation, Harrisburg, PA. This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111 1of4 All Intemational Rights Reserved. For latest revision call the AMP FAX* number. AMP FAX/PRODUCT INFO 1-800-822-6752 *Trademark Loc B Crimping Die Assemblies 356611-1, 356611-2, and 356612-1 408-4324 Front of Crimping Chamber Stripped Wire Crimper Locator/Wire Stop in Contact Locator Slot Figure 3 3. Inserl a properly strioped wire into the contact wire barrel until it butts against the locatorAwvire stop. 4. Hold the wire in place and actuate the tooling through a complete cycle. 5. Allow the dies to open FULLY, then remove the crimped contact. 4. MAINTENANCE AND INSPECTION 4.1. Daily Maintenance iis recommended that each operator of the die assemblies be made aware of, and responsible for, the following four 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. 2. Make sure that the proper die holding screws are in place and are secured with the proper washers and retaining rings. Check die alignment and tighten die holding 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, store them in a clean, dry area. 4.2. Periodic Ingpaction Reqular inspections should be performed by quality contrel personnel with a record of scheduled inspection remaining with the dies 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 all die holding screws, washers, retaining rings, and die componenis are in place. 3. Check all bearing surfaces for wear. Replace worn components (refer to Section 5, REPLACEMENT AND REPAIR). 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 5, REPLACEMENT AND REPAIR. 4.3. Crimp Height Inspection This inspection requires the use of a micrometer with a modified anvil, as shown in Figure 4. It is recommended using the meditied micrometer (Crimp Height Comparator RS-1019-5LP} which may be purchased from: VALCO 1410 Stonewood Drive Bethlehem, PA 18017-3527 Shearer Industrial Supply Co. 20 North Penn Street or York, PA 17401-1014 20f4 Rev A Crimping Die Assemblies 356611-1, 356611-2, and 356612-1 408-4324 Position Point on Center of Wire Barrel Opposite Seam _-7iL | Modified Crimp Anvil Height WIRE SIZE (AWG) CRIMP HEIGHT DIMENSION (Max) (+0.05 [+.002]) 8 2.79 [.110] 10 2.54 [.100] 14 2.11 [.083] Figure 4 Proceed as follows: 1. Select a contact and a wire for the crimping die to be inspected. 2. Crimp the contact according to Section 3, CRIMPING PROCEDURE. 3. Using the crimp height comparator, measure the wire barrel crimp height as shown in Figure 4. Ifthe crimp height conforms to the dimension indicated, the die assembly is considered dimensionally correct. If not, return the die assembly for evaluation and repair (refer to Section 5, REPLACEMENT AND REPAIR). For additional information concerning the use of the crimp height comparator, refer to 408-7424. 5. REPLACEMENT AND REPAIR Customerreplaceable parts are listed in Figure 5. A complete inventory should be stocked and controlled to prevent lost time when replacement of parts is necessary. Order replacement parts or additional die assemblies through your Tyco representative, or call 1-800-526-5142, or send a facsimile of your purchase order to 717-986-7605 or write to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 Die assemblies may be returned for evaluation and repair. For repair service, contact a representative at 1-800-526-5136. 6. REVISION SUMMARY Per EC: 0990-0059-00 Updated document to corporate requirements * Changed repair service information in Section 5 * Added new Section 6, REVISION SUMMARY RevA 3of4 Crimping Die Assemblies 356611-1, 356611-2, and 356612-1 408-4324 33.27 (131 OL \___| _ 15.88 __, | 16.26 [.625] [.640] Weight: 113.4 g [4 02] (Approx) CUSTOMER REPLACEMENT PARTS PART NUMBER FOR DIE ASSEMBLY ITEM DESCRIPTION ARSE AIBLY 356611-1 356611-2 356612-1 1 662369-1 662369-2 662367-1 ANVIL, Wire 1 2 662370-1 662370-1 6623641 LOGATOR/WIRE STGP 1 3 662371-1 662371-1 662368-1 SUPPORT, Wire Anvil 1 4 662372-1 662372-1 662365-1 SUPPORT, Upper 1 5 662373-1 662373-2 662366-1 CRIMPER, Wire 1 6 1-306593-4 SCREW, Die Holding 2 7 24088-7 WASHER, Curved 2 8 305182 SPRING 2 ] 1-21046-3 RING, Retaining 2 Figure 5 4of4 Rev A