408-2433

Insulation Piercing COPALUM Terminal and Splice Crimping Heads

Rev A

6 of 8

Tyco Electronics Corporation

4.4. Die Closure Inspection

Every crimping head is inspected for proper die

closure before packaging. An inspection should be

performed periodically to check the die closure for

excessive wear. The die closure inspection is

accomplished using the GO NO–GO plug gages.

Tyco Electronics neither manufactures nor sells plug

gages. A suggested plug gage design and the GO

NO–GO dimensions of the plug gage members are

listed in Figures 7 and 8. the following procedure is

recommended for inspecting the die closures.

1. Clean oil or dirt from die closure areas, and plug

gage members.

2. Select the proper GO gage. Position gage

member in lower jaw inner crimp closure so that

locator is in notch of gage member. See Figure 9,

Detail A.

3. Close the crimping jaws until they are bottomed

but not under pressure.

4. To meet the GO gage conditions, the plug gage

must be free to rotate in either direction as shown

in Figure 9, Detail A.

5. Select the proper NO–GO gage. Position gage

member in lower jaw inner crimp closure so that

locator is in notch of gage member. See Figure 9,

Detail B.

6. Close the crimping jaws so that inner crimp

surfaces are seated on the NO–GO member.

Inner Crimp Die

Closure Configuration

A" Dim.

B" GODim.

50.8 [2.00] Min.

F"

D"

C"

1/2 C"

G"

E" Dia.

B" NO-GO Dim.

SUGGESTED PLUG GAGE DESIGN - INNER CRIMP

HEAD

DIE CLOS. DIM'S. A"

GAGE MEMBER{ DIM'S. B"

DIA.

C"

D"

E" DIA.

F"

G"

GO}

NO-GO

GO

NO-GO

68081

2.30

[.1180]

3.25

[.1280]

2.997-3.005

[.1180-.1183]

3.249-3.251

[.1279-.1280]

1.65 [.065] 7.37 [.290] 1.65 [.065] 7.87 [.310] 0.61 [.024]

68082

3.28

[.1290]

3.53

[.1390]

3.277-3.284

[.1290-.1293]

3.528-3.531

[.1389-.1390]

1.90 [.075] 7.62 [.300] 1.90 [.075] 8.89 [.350] 0.61 [.024]

Figure 7

Outer Crimp Die

Closure Configuration

H" Dim.

P" GODim.

50.8 [2.00] Min.

M"

K"

J"

1/2 J"

N"

L" Dia.

P" NO-GO Dim.

SUGGESTED PLUG GAGE DESIGN - OUTER CRIMP

HEAD

DIE CLOS. DIM'S. H"

GAGE MEMBER{ DIM'S. P"

DIA.

J"

K"

L" DIA.

M"

N"

GO}

NO-GO

GO

NO-GO

68081

4.445

[.1750]

4.801

[.1890]

4.445-4.453

[.1750-.1753]

4.798-4.801

[.1889-.1890]

2.29 [.090] 3.30 [.130] 2.29 [.090] 7.87 [.310] 1.14 [.045]

68082

4.953

[.1950]

5.309

[.2090]

4.953-4.961

[.1950-.1953]

5.306-5.309

[.2089-.2090]

2.54 [.100] 3.30 [.130] 2.54 [.100] 8.89 [.350] 1.50 [.059]

{Material - Tool Steel;

}GO" die closure dimensions apply when jaws are bottomed, but not under pressure

Figure 8