Cisco 95-0669-01 - C1-1

Part Number/ Ver .
95-0669-01 Rev C1
Description: Mechanical Acceptance Specification
Document Number: 95-0669-01

Revision: C1
Originator: Jim Cushman
Department: Engineering Approvals
Approval
Department Name
Date
NPI Danny Tan () 04/14/99
Design Eng. Jim Cushman () 02/26/99
NPI Mech Mgr Sherman Leung ()
Mech Eng Mgr Saeed Seyedarab()
Modification History
Rev RCN # Date Originator Comment

B0 R99-6237 04/30/99 Jim Cushman Initial Release
For cosmetic spec requirements only, refer to 95-

C0 E005928 07/25/00 Masood Baig 2733-01. 95-2733-01 supercedes this specifica
tion for all Cisco cosmetic requirements
C1 E081125 01/26/05 Serv Goyal Restore corrupt figures on previous revisions
PAGE NUMBER
The information presented in this form is the property of Cisco Systems Incorporated; it is considered confidential and propri-
etary. All unauthorized use or reproduction is prohibited without the specific written permission of Cisco Systems, Inc..
Page 1 of 15
Si este es una copia, a menos que se especifique lo contrario es una copia no controlada, deberá verificar su revisión antes de su Uso.
Part Number/ Ver. 95-0669-01 Rev C1
TABLE OF CONTENTS
1.0 INTRODUCTION ....................................................................................................................3

1.1 Scope.........................................................................................................................................3
1.2 General ......................................................................................................................................3
1.3 Reference Documents ..............................................................................................................3
1.4 Definitions ................................................................................................................................3
1.5 Procurement ..............................................................................................................................4
2.0 SHEET METAL .......................................................................................................................4
2.1 Dimensions ...............................................................................................................................4
2.2 Process Acceptance Criteria .....................................................................................................4
2.3 Surface Quality .........................................................................................................................6
2.4 Inspection of Sheet Metal Parts ................................................................................................6
3.0 ASSEMBLIES ..........................................................................................................................7
3.1 Separable Assemblies ...............................................................................................................7
3.2 Inseparable Assemblies.............................................................................................................7
3.3 Inspection of Inseparable Assemblies.......................................................................................9
4.0 PLASTIC ..................................................................................................................................9
4.1 Requirements for Plastic Molded Parts ....................................................................................9
4.2 Surface Quality .........................................................................................................................9
4.3 Inspection of Plastic Parts.........................................................................................................10
5.0 MISCELLANEOUS .................................................................................................................10
5.1 Labels / Overlays ......................................................................................................................10
5.2 Elastomers, Feet and Bumpers..................................................................................................10
5.3 Mechanical Fasteners................................................................................................................10
6.0 FINAL FINISH.........................................................................................................................11
6.1 General ......................................................................................................................................11
6.2 Surface Preparation...................................................................................................................11
6.3 Paint ..........................................................................................................................................11
6.4 Physical Requirements-Pain .....................................................................................................12
6.5 Performance Requirements.......................................................................................................12
6.6 Plating ......................................................................................................................................13
7.0 SILK-SCREEN / PAD PRINTING .........................................................................................13
7.1 Color ........................................................................................................................................13
7.2 Silkscreen / Pad Printing Acceptance .....................................................................................13
8.0 PACKAGING ..........................................................................................................................15
8.1 Part Identification ....................................................................................................................15
8.2 Painted Parts ............................................................................................................................15
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1.0 INTRODUCTION
1.1 Scope
This document establishes the acceptance criteria for finished products.
If a conflict between this document and the part documentation occurs the information
contained within the part document shall take precedence.
1.2 General
This document defines the limits of acceptability for all sheet metal, plastics, assemblies
and finished products.
1.3 Reference Documents

UL 1439 Determination of Sharpness of Edges on equipment.
95-0735-01 Tolerance Specification for Soft and Hard Tooled Sheetmetal.
1.4 Definitions
ABRASIONS- A mark or series of marks on a surface which interrupts the perceived
continuity of the surface. These marks are usually observed as changes in shade or gloss of
the material surface.
BURRS- Thin ridges of base material at the juncture of the material face and cut ridge.
CRACKS- A line or group of lines resulting in material separation.
EJECTOR PINS- On plastic or hard elastomer parts, a pin or series of pins mounted in one
side of the mold. On mold opening, pins push against the base material breaking it free from
the cavity.
FLASH- In plastic or hard elastomer parts. A thin portion of the melt which extends beyond
the body of the part that occurs at mating portion of molds.
GALLING- A single line or series of gouging or dragging on the surface of the part.
GATES- An orifice through which the melted plastic enters the mold cavity.
ORANGE PEELS- A defect in painted surfaces that has the appearance of the skin on a
orange.
SINK- On plastic parts an area that is slightly depressed from the surrounding surface,
caused by the cooling process on parts with uneven thickness.
SLIVERS- Small quantities of shaving scrap which may be connected to or embedded in the
surface of the part.
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SLUG MARKS- Marks that result from loose pieces of material being embedded in the
surface of the part.
TEARS- A line, hole or flaw resulting in material separation.
VOIDS- AN internal, bubble like unfilled space. Not necessarily visible from any surface.
1.5 Procurement
Purchase orders for parts procurement shall have the following information
A. When re-ordering existing parts, the purchase order shall list the current revision level. A copy
of the documentation may or may not be included with the P.O.
B. On new or new revision parts and when a new vendor is used, the purchase order shall list
the current revision level and must include a copy of the latest documentation.
2.0 SHEETMETAL
2.1 Dimensions
All dimensions apply after final finish.
2.1.1 Hole tolerances are +.003/-.002 (+0.08/-0.05mm).
2.2 Process Acceptance Criteria
2.2.1 Bulges do to forming (FIG. 1)

Bulges produced at the form are acceptable and need not be within size limits.
FIG. 1
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2.2.2 Bulges Due To Perforations (FIG. 2)

Bulges due to the closeness of perforations near the edge of the part shall be cause for
rejection if the dimension limits are exceeded.
FIG. 2
2.2.3 Extruded Holes (FIG. 3)

Tears and cracks which extend into to hole and exceed .4h (.4 X h) in height or length are
unacceptable.
I CRACK
.4h MAX .--J

.4h MAX
TEAR-
FIG. 3
2.2.4 Burrs
Implied burr limits shall meet the following:
a. Burr height shall not exceed 10% of the stock thickness and shall not exceed the
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dimensional limits of the feature.
b. There shall be no burrs which can cause personal injury. As a referee decision, the test
apparatus and method described in UL 1439 shall be used.
2.2.5 Flatness
With part unrestrained and at rest on a horizontal surface, the flatness shall not exceed
.004 times the diagonal length (.004 X L.).
2.3 Surface Quality

The conditions listed below apply to unplated or preplated parts only. The finished parts must
conform to any subsequent painting or other surface treatment requirements.
2.3.1 Acceptable Conditions

a. Abrasions- Evidence of abrasions on the cosmetic surface of a part made from preplated
material is acceptable. For parts specifying a finishing operation the abrasion must be
controlled such that the finishing operation will conceal all marks.
b. Die Pressure Marks- Are acceptable if the specified appearance and functional
requirements of the part are met.
c. Galling- This condition is acceptable if the dimensional and appearance requirements

of the part are met.
d. Rough Areas- Parts which display areas that are visually rougher than the surrounding
surfaces can be accepted if the dimensional requirements are met. Rough areas on
cosmetic surfaces are not acceptable.
e. Stretcher Strains- This condition is acceptable if the appearance requirements of the

parts are met.
2.3.2 Unacceptable Conditions

a. Dirt- The presence of accumulated foreign material on a part is unacceptable. Any
cleaning process on a part that could corrode, must be followed by the addition of a
surface treatment that will prevent rust formation.
b. Forming- Fracture or material failure on the outside of a form is not acceptable.
c. Pre finished Material Damage- Evidence of scratches, digs, or slug marks on cosmetic
surfaces of a part is not acceptable.
d. Slivers- Any appearance of slivers connected to or embedded in a part, including a part

with subsequent finishing operation is unacceptable.
e. Slugs- Any slug or scrap of material being embedded in a part is unacceptable.
2.4 Inspection of Sheetmetal Parts

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a. Vendor will furnished a complete first article inspection report covering all dimensions
shown on Cisco Systems, Inc. supplied documentation.
b. Subsequent inspection reports as agreed upon between vendor and Cisco Systems, Inc.
3.0 ASSEMBLIES
3.1 Separable Assemblies

Must meet all criteria specified on the documentation and process control forms.
3.1.1 Fasteners
Screws and nuts must be tightened to torque specified in Cisco Specification no.
701103-0000. Screws and other fasteners must not chip or crack any painted surface after
tightening. Fasteners with head driving recesses that are marred, burred or damaged,
threads disturbed or damaged, visible corrosion and chipped or peeled plating or paint
are unacceptable. Fasteners are to be in complete contact with the base material.
3.1.2 Labels
Labels shall not have any blisters, wrinkles or air pockets visible after assembly and will
not exhibit any tears or cracks.
3.2 Inseparable Assemblies
3.2.1 Dimensions
Must meet all criteria specified on the documentation and process control forms
All dimensions apply after final finish.
3.2.2 Captive Fasteners (Press Type)

a. Fasteners must be flush with the base material and meet all installation procedures and
performance data as stated in the manufacturers specifications.
b. Fasteners are not to be crushed or deformed during installation.
c. Base material around the fastener shall not be deformed or bulged during installation.
d. Longer captive fasteners, such as studs and standoffs, etc. must be perpendicular to
base material within 1.5 degrees.
e. Locating dimensions and their respective tolerances on all captive fasteners apply at
the point of entry of mating part, see FIG. 4.
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FIG. 4
3.2.3 Captive Fasteners (Swage Type)
a. Fasteners must be flush with the base material and meet all installation procedures and
performance data as stated in the manufacturers specifications.
b. Fasteners are not to be crushed or deformed during installation.
c. Base material around the fastener shall not be deformed or bulged during installation.
d. Longer captive fasteners, such as studs and standoffs, etc. must be perpendicular to base
material within 1.5 degrees.
e. Locating dimensions and their respective tolerances on all captive fasteners apply at the
point of entry of mating part, see FIG. 4.
3.2.4 Rivets
Rivet head must be flush with base material. Pop-rivets must be of a style that does not
allow the mandrel or anvil to separate from the body of the rivet.
Clinching portion and head of rivet must be flush with the base material. Any play or
looseness between riveted part is not acceptable.
3.2.5 Welding
Spot welding size, quantity and location at vendors option.
Spot weld marks on cosmetic surfaces of painted parts must be filled prior to painting.
Fillet weld size and location at vendors option.
Splatter or other potentially loose particles caused by any welding process are not
permissible.
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3.2.6 Labels
Labels, after assembly shall not exhibit any blisters, wrinkles, air bubbles, tears or cracks.
3.3 Inspection of Inseparable Assemblies

b. Subsequent inspection reports as agreed upon between vendor and Cisco Systems, Inc.
4.0 PLASTIC
4.1 Requirements For Plastic Molded Parts

Molded parts shall be of uniform quality and the supplier shall not change material
formulation or process without Cisco Systems, Inc. written approval.
Regrind material is permissible, but must not exceed UL limits.
4.1.1 Flash Removal

Flash at parting lines and cavity match lines shall be trimmed flush to .016” above or
below the adjacent surface.
Holes and through openings containing flash shall be within the stated size limits.
4.1.2 Ejector Pin Marks

Ejector pin marks shall be flush to .016” above or below the adjacent surface
Ejector pin location shall be at vendors option subject to written approval from Cisco
Systems. Inc.
4.1.3 Gates
Gates shall be removed flush to .016” above or below the adjacent surface.
4.2 Surface quality
4.2.1 Surface Imperfections

Imperfections such as weld lines, seam lines, sinks, voids, etc. are not acceptable on
cosmetic surface. Cosmetic surfaces must be identified on documentation.
4.2.2 Acceptable Surface Imperfections

Surface imperfections as stated in paragraph 4.2.1 are acceptable on non-cosmetic
surfaces.
4.2.3 Voids
Voids in non-cosmetic surfaces are permissible, unless part failure could be caused by
such voids.
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4.3 Inspection of Plastic Parts
b. Subsequent inspection reports as agreed upon between vendor and Cisco systems, Inc.
5.0 MISCELLANEOUS
5.1 Labels/Overlays
5.1.1 All labels/overlays are to be die cut, with Kraft paper backing.
5.1.2 Adhesive type to be suitable for use on electro galvanizes or plated sheet metal, plastics
and painted surfaces
5.1.3 All corners on labels/overlays are to have a .03 minimum radius.
5.1.4 Packaging to conform to “Bag and Tag” as described in paragraph 8.1.2 of this specification.
5.1.5 Storage of labels/ overlays with the following adhesive.

a. Acrylic- Store for one year maximum from purchase date at room temperature
conditions of 72 degrees F (22 degrees C) and 50% R.H.
b. Rubber base- Maximum storage of six months from date of purchase date when stored
at room temperature conditions of 72 degrees F, (22 degrees C) and 50% R.H.
5.2 Elastomer Feet and Bumpers
5.2.1 Elastomer feet and bumpers must be of a non-marring material.
5.2.2 Adhesive backing, if required, to be suitable for use on electro galvanizes or plated sheet metal,
plastics and painted surfaces
5.2.3 Packaging to conform to “Bag and Tag” as described in paragraph 8.1.2 of this specification.
5.2.4 Store for one year maximum from purchase date at room temperature conditions of 72
degrees F, (22 degrees C) and 50% R.H.
5.3 Mechanical Hardware

All mechanical hardware i.e. screws, nuts, washers, rivets, etc. shall conform to
“INDUSTRIAL FASTENERS INSTITUTE” Fasteners Standards, latest edition.
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6.0 FINAL FINISH
6.1 General
This portion of the specification defines the requirements of all surface coatings (paint or
plating which are intended for use on equipment parts where a decorative appearance and
protection are of primary concern.
6.2 Surface Preparation
6.2.1 Metal
Surface must be free of dirt, grease, fingerprints, oxidation products and other
contaminants to insure optimum adhesion and coating performance properties.
6.2.2 Plastic
Surface must be free of mold release, dirt, fingerprints and all other foreign matter to insure
optimum adhesion and coating performance properties.
6.3 Paint
6.3.1 Type 1, Class A, Smooth

Very critical decorative and protective finish. Class A surfaces, when viewed with
uniform non-directional illumination between 80 and 150 foot candles at a distance 18”
for 10 seconds shall not exhibit or reflect any discernible imperfections. Imperfections will
include. but not be limited to scratches, runs, orange peels, pits, wrinkles, grit, dust or
other foreign matter and may not be of a nature that will affect adhesion or fundamental
corrosion proofing properties.
6.3.2 Type 2, Class B, Smooth

Protection against corrosion, non-critical finish. Class B surfaces, when viewed when
viewed with uniform, non-directional illumination between 80 and 150 foot candles at a
distance of 24” for 10 seconds shall not exhibit or reflect more than 3 imperfections per
square foot of finished surface. Imperfections shall not exceed .020” in distance,
imperfections will be considered the same as those listed under Class A, and may not be
of a nature that affects adhesion or fundamental corrosion proofing properties.
6.3.3 Type 3, Class C, Texture

Decorative and protective finish, primarily used on the outside of cabinets. The smooth
finish (base coat) prior to texturing shall conform to the material process for class B
smooth. Class C surfaces, when viewed with uniform, non-directional illumination
between 80 and 150 foot candles at a distance of 30” for 10 seconds shall not exhibit or
reflect imperfections readily apparent against the textured background. Imperfections will
be considered the same as those listed under Class A, and may not be of a nature that
will reduce the adhesion, corrosion proofing or chemical resistance properties of the
coating, or disrupt the pattern uniformity. On large finished surfaces, such as cabinets, the
criteria for rejection shall be based on general over-all quality, not on specific numbers of
imperfections, except that these criteria may be used as a general guide to the quality
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level desired.
When viewed at a distance of 30” for 5 seconds, at an angle of 45 degrees +/- 15 degrees, any
indentation, any indentation, without Cisco Systems prior approval is unacceptable.
6.4 Physical requirements- Paint
6.4.1 Color
To match color chip supplied by Cisco Systems, Inc. Color tolerance is +/- 0.50 Delta Lab.
6.4.2 Dry Film Thickness

Using any reliable film thickness gauge, make four measurements at various locations.
The resulting average will be the film thickness.
6.4.3 Thickness Tolerance

Smooth finish= .0020 +/-.0010
Textured finish= .0034 +/-.0010
6.4.4 Texture
Must match the color/texture panel as to size, population and profile. Comparison
Technique. Place the textured panel flat against the surface being inspected. The pattern
should match as defined in paragraph 6.3.3 Type 3, Class C, Texture. Min./max. texture
chips to be furnished by Cisco Systems, Inc.
6.5 Performance requirements- Paint
6.5.1 Pencil Hardness

2 H minimum.
6.5.2 Adhesion Test

Crosshatch adhesion test.
Using a razor blade and a ruler, cut 11 parallel lines through the film, 1” long, .10” apart.
Repeat the same procedure at right angles to the first 11 lines, forming a cross hatch area
of one square inch. Place a pressure sensitive cellophane tape (3M no. 3531 or equivalent)
over the crosshatched area, force out any entrapped air. After 5 minutes, with an abrupt
motion (do not yank), remove the tape. Small flakes of paint may be removed along edges
and intersections of cuts. The paint loss area can not exceed 15% of the lattice.
6.5.3 Abrasion Resistance

Taber abrasion resistance test.
<100 milligrams loss/1000 cycles, CS17 wheel, 1000 gram load.
6.5.4 Humidity Resistance

Must pass 100 hours @ 100 degrees F, 100% R.H. without blisters or loss of adhesion.
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6.5.5 Salt Spray
With an “X” scribed on a panel and at 95 degrees F, apply a 5% salt solution, after 100
hours, there shall be no more than .125” rust creepage at the scribe mark.
6.5.6 Chemical Resistance

Methyl Ethyl, Ketone (MEK) resistance.
20 double rubs with a clean cloth which has been dipped into a MEK (quite damp, but not
soaked) shall leave slight to no burnish.
6.6 Plating
6.6.1 Zinc, Clear Chromate, .0005 to .0010” thick.

Generally not intended for use on cosmetic surfaces. Either bright or dull finish is
acceptable. Parts having a hardness of Rc-40 or greater must be given a heat treatment
prior to plating. Springs having a hardness over Rc-40 must be given a post bake at
350/400 degrees for 3 hours.
6.6.1.1 Acceptance Criteria

Part finish shall be uniform across each surface and throughout a given lot. Parts shall
be free of chemical residue, stains, blisters, peeling, flaking, cracks and water spots.
Rack marks are acceptable unless otherwise specified.
6.6.2 Bright Nickel, Electroplate, Decorative, .0004 to .0008” thick.

In most cases will be used for cosmetic purposes. Parts having a hardness of Rc-40 or
greater must be given a post bake at 350/400 degrees F for 3 hours.
6.6.2.1 Acceptance Criteria

Part finish shall be uniform and without color discontinuities. Plating thickness to be
within limits specified, shall be free of chemical residue, stains, blisters, peeling,
flaking, cracks water slots and other surface defects. Rack marks within a specified
cosmetic surface are unacceptable.
7.0 SILKSCREEN/ PAD PRINTING
7.1 Color
Color to match colors specified on documentation.
7.2 Silkscreen / Pad Printing Acceptance (FIG. 5)
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SPLArrER--\
EDGE D,I;;FINITION:--
tl/OTSHARP
FIG. 5
7.2.1 Edge Definition
Edge definition shall be sharp and clean without bleeding, splatter, discontinuity, breaks
in letters or lines and any other visual defects when viewed with white fluorescent
illumination at a distanc of 18” for 10 seconds.
7.2.2 Voids
When viewed with cool white fluorescent illumination at a distance of 18” for 10 seconds
part shall not exhibit any pits, voids, blemishes or any other visual defect.
7.2.3 Adhesion
The silkscreen/pad printing must be able to withstand the following tape test without
exhibiting any flaking, peeling, or removal of characters and lines. Firmly rub a strip of
semi-transparent, pressure sensitive adhesive tape (3M Highland adhesive tape or
equivalent) over the printing. Within 90 seconds of application, rapidly remove the tape by
pulling back upon itself. Using fresh tape, repeat the above, testing the same area, except
pull the tape at an angle of 90 degrees.
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8.0 PACKAGING
8.1 Part Identification

Parts are to be identified as follows.
The documentation for each part is to specify what type of part identification is required.
8.1.2 Bag and Tag

Parts are to be placed in bags or boxes and the bag or box shall be stamped with part no.,
current revision level, quality control identification number and manufactured date code.
8.1.3 Part Stamp

Stamp part in area indicated on documentation with the part no., current revision level,
quality control identification number and manufactured date code. The stamp is to be a
metal stamp or indelible ink of a contrasting color. Character height to be .12” minimum.
8.2 Painted Parts

Painted parts must not be packaged in plastic bags until the paint is completely cured.
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Part Number/ Ver .

Description: Mechanical Acceptance Specification

Document Number: 95-0669-01

NPI Danny Tan () 04/14/99

Design Eng. Jim Cushman () 02/26/99

NPI Mech Mgr Sherman Leung ()

Mech Eng Mgr Saeed Seyedarab()

Rev RCN # Date Originator Comment

For cosmetic spec requirements only, refer to 95-

Description: Mechanical Acceptance Specification

1.0 INTRODUCTION ....................................................................................................................3

Description: Mechanical Acceptance Specification

1.3 Reference Documents

CRACKS- A line or group of lines resulting in material separation.

Description: Mechanical Acceptance Specification

TEARS- A line, hole or flaw resulting in material separation.

2.1.1 Hole tolerances are +.003/-.002 (+0.08/-0.05mm).

2.2 Process Acceptance Criteria

2.2.1 Bulges do to forming (FIG. 1)

Description: Mechanical Acceptance Specification

2.2.2 Bulges Due To Perforations (FIG. 2)

2.2.3 Extruded Holes (FIG. 3)

.4h MAX .--J

Description: Mechanical Acceptance Specification

2.3 Surface Quality

2.3.1 Acceptable Conditions

c. Galling- This condition is acceptable if the dimensional and appearance requirements

e. Stretcher Strains- This condition is acceptable if the appearance requirements of the

2.3.2 Unacceptable Conditions

b. Forming- Fracture or material failure on the outside of a form is not acceptable.

d. Slivers- Any appearance of slivers connected to or embedded in a part, including a part

e. Slugs- Any slug or scrap of material being embedded in a part is unacceptable.

2.4 Inspection of Sheetmetal Parts

Description: Mechanical Acceptance Specification

3.1 Separable Assemblies

3.2 Inseparable Assemblies

3.2.2 Captive Fasteners (Press Type)

b. Fasteners are not to be crushed or deformed during installation.

Description: Mechanical Acceptance Specification

b. Fasteners are not to be crushed or deformed during installation.

Fillet weld size and location at vendors option.

Description: Mechanical Acceptance Specification

3.3 Inspection of Inseparable Assemblies

4.1 Requirements For Plastic Molded Parts

Regrind material is permissible, but must not exceed UL limits.

4.1.1 Flash Removal

4.1.2 Ejector Pin Marks

4.2 Surface quality

4.2.1 Surface Imperfections

4.2.2 Acceptable Surface Imperfections

Description: Mechanical Acceptance Specification

5.1.3 All corners on labels/overlays are to have a .03 minimum radius.

5.1.5 Storage of labels/ overlays with the following adhesive.

5.2 Elastomer Feet and Bumpers

5.2.1 Elastomer feet and bumpers must be of a non-marring material.

5.3 Mechanical Hardware

Description: Mechanical Acceptance Specification

6.2 Surface Preparation

6.3.1 Type 1, Class A, Smooth

6.3.2 Type 2, Class B, Smooth

6.3.3 Type 3, Class C, Texture

Description: Mechanical Acceptance Specification