408-1724
Crimping Dies 48858-1 through 48861-1
5 of6
Rev N
Tyco Electronics Corporation
50.8 [2.00]
Min Typ
GO Diameter
NO-GO Diameter
SUGGESTED PLUG GAGE DESIGN - WIRE BARREL CRIMP
Die Closure
Configuration
TOOL
GAGE ELEMENT DIAMETER
NUMBER
GO
NO-GO
48858-1
5.105-5.113 [.2010-.2013]
5.255-5.258 [.2069-.2070]
48859-1
6.020-6.027 [.2370-.2373]
6.170-6.172 [.2429-.2430]
48860-1
6.833-6.840 [.2690-.2693]
6.982-6.985 [.2749-.2750]
48861-1
8.103-8.110 [.3190-.3193]
8.252-8.255 [.3249-.3250]
Figure 8
SUGGESTED PLUG GAGE DESIGN - INSULATION BARREL CRIMP
GO
NO
GO
GO Dimension D"
Dimension F"
Min (Typ)
Die Closure
Configuration
NO-GO Dimension D"
Dimension E" (Typ)
TOOL
GAGE ELEMENT DIMENSION D"
DIMENSION
DIMENSION
NUMBER
GO
NO-GO
E"
F"
48858-1
3.861-3.868 [.1520-.1523]
4.366-4.369 [.1719-.1720]
7.14 [.281]
48859-1
4.216-4.224 [.1660-.1663]
4.722-4.724 [.1859-.1860]
7.87 [.310]
4.83 [.190]
48860-1
4.115-4.122 [.1620-.1623]
4.620-4.623 [.1819-.1820]
8.13 [.320]
48861-1
4.623-4.630 [.1820-.1823]
5.128-5.131 [.2019-.2020]
10.29 [.405]
6.35 [.250]
Figure 9
7. Loosen socket head cap screws from both
stationary and moving insulation dies and move
pin–keys all the way out so that insulation crimping
sections of dies are in the tight position.
See Figure 10, Detail B.
8. Press and hold insulation die down against
pin–key, and tighten the socket head cap screws.
9. With wire barrel dies bottomed, inspect the
insulation crimp die closure using the proper plug
gage in the same manner as steps 3 through 5.
See Figure 10, Detail B.
10. If both wire barrel and insulation die closures
meet the plug gage conditions, the dies are
considered to be dimensionally correct.
5. REPLACEMENT AND REPAIR
The parts listed in Figure 11 are customer–
replaceable. A complete inventory can be stocked
and controlled to prevent lost time when replacement
of parts is necessary. Order replacement parts
through your Tyco Electronics 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 (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
Dies may be returned for evaluation and repair. For
die repair service, contact a representative at
1–800–526–5136.
6. REVISION SUMMARY
S
Updated document to corporate requirements
S
New format
