408-2281
7
of 8
Rev
CD
6.2. Gaging the Die Assembly
It is highly recommended to gage the die assembly
at the beginning of a run, after changing a die
assembly — and then periodically during the run.
Inspect the wire barrel section and insulation sealing
section of the crimping chamber using plug gages that
conform to the measurements provided in Figure 7 as
follows:
Gages can be purchased from:
Pennoyer-Dodge Company
6650 San Fernando Road, Glendale, CA 91201
1. Mate the dies until it is evident that they have
bottomed. Hold the dies in this position.
2. Align the GO element of the plug gage with the
crimping chamber. Push the element straight into
the crimping chamber as shown in Figure 8. The
GO element must pass completely through the
crimping chamber.
3. Align the NO-GO element with the crimping
chamber and try to insert it straight into the crimping
chamber. The NO-GO element may start entry, but
must not pass completely through as shown in
Figure 8.
If the crimping chamber conforms to the gage
inspection, the die assembly is considered dimensionally
correct. If not, the die assembly must be replaced.
6.3. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the dies and/or be supplied to
personnel responsible for the dies. Although
recommendations call for at least one inspection a
month, the inspection frequency should be based on
the amount of use, ambient working conditions, operator
training and skill, and established company standards.
This inspection should be performed as follows:
1. Remove all lubrication and accumulated film by
immersing the die assembly in a suitable
commercial degreaser that will not affect the painted
alignment dots.
2. Inspect the crimp area for flattened, chipped,
cracked, worn, or broken areas. If damage is
evident, the die assembly must be replaced.
7. REPLACEMENT AND REPAIR
Order die assemblies through your TE Representative,
or call 1-800-526-5142, or send a facsimile of your
purchase order to 1-717-986-7605, 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, call 1-800-526-5136.
8. REVISION SUMMARY
Revisions to this instruction sheet include:
•
Updated dimensions in Figure 6 and text in
Paragraph 6
Figure 7 (Cont’d)
NOTE
i
NOTE
i
DIE
ASSEMBLY
GAGE ELEMENT
C
(Exposed
Length)
R
Radius
(Max)
GO
NO-GO
59877-1
7.518-7.526
[.2960-.2963]
7.769-7.772
[.3059-.3060]
9.91
[.390]
7.62
[.300]
68006
-0
2.870-2.877
[.1130-.1133]
3.045-3.048
[.1199-.1200]
6.35
[.250]
3.18
[.125]
68007
-0
3.200-3.208
[.1260-.1263]
3.375-3.378
[.1329-.1330]
6.35
[.250]
3.556
[.140]
68008
-1
68008-1
3.937-3.944
[.1550-.1553]
4.112-4.114
[.1619-.1620]
6.35
[.250]
4.34
[.171]
68009
-0
5.003-5.011
[.1970-.1973]
5.179-5.181
[.2039-.2040]
9.91
[.390]
5.54
[.218]
68010
-0
6.197-6.205
[.2440-.2443]
6.372-6.375
[.2509-.2510]
9.91
[.390]
6.73
[.265]
68010-2
6.579-6.586
[.2590-.2593]
6.754-6.756
[.2659-.2660]
9.91
[.390]
6.73
[.265]
68011-1
7.924-7.932
[.3120-.3123]
8.100-8.102
[.3189-.3190]
9.91
[.390]
7.52
[.296]
314948-1
9.550-9.558
[.3760-.3763]
9.802-9.804
[.3859-.3860]
9.91
[.390]
8.13
[.320]
314964-1 10.922-10.930
[.4300-.4303]
11.097-11.100
[.4369-.4370]
9.91
[.390]
7.52
[.296]
1976441-1
7.924-7.932
[.3120-.3123]
8.100-8.102
[.3189-.3190]
9.91
[.390]
7.52
[.296]
1976442-1
7.518-7.526
[.2960-.2963]
7.769-7.772
[.3059-.3060]
9.91
[.390]
7.62
[.300]
1976443-1
9.550-9.558
[.3760-.3763]
9.802-9.804
[.3859-.3860]
9.91
[.390]
8.13
[.320]
Suggested Plug Gage Design for
Wire Barrel Section of Crimping Chamber
Die Closure
Configuration
GO
Gage Element
NO-GO
Gage Element
25.4 [1.00]
Min Typ
C
R
