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Instruction Sheet
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
408-2281
Crimping Die Assemblies for
COPALUM* Sealed Terminals and Splices
07 MAR 14 Rev CD
Figure 1
1. INTRODUCTION
The crimping die assemblies are designed to be
installed into the hydraulic crimping heads listed in
Figure 1 and are used to crimp COPALUM sealed
terminals and splices. Read these instructions
thoroughly before crimping any terminals or splices.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Illustrations
are for reference only and are not drawn to scale.
2. DESCRIPTION
Each crimping die assembly consists of a stationary
dies (nest) and moving die (anvil). Each die features
an alignment dot on the front of the die. See Figure 1.
3. DIE ASSEMBLY INSTALLATION
For information concerning die installation and general
performance of the hydraulic crimping head, refer to
the instruction sheet packaged with the crimping head.
To avoid personal injury, ALWAYS DISCONNECT
electrical and air supply to power unit before
installing the hydraulic crimping head or die
assembly.
In order to achieve proper mating of the dies during
installation, ensure that:
— the shanks of the dies are offset to the same
surface of the die, but that the alignment dots
align and face the operator
— the anvil moves and the nest is stationary
DO NOT mix dies from different or the same die
assemblies (because of inconsistent wearing) —
it is important that the dies are used as the set.
To avoid personal injury, make sure to close the
yoke of the hydraulic crimping head and fully insert
the pin. When operating the power unit, be careful
when handling terminals, splices, or wire near the
crimping area of the die assembly.
4. CRIMPING PROCEDURE
Select the die assembly and terminal or splice, and
prepare the wire as follows:
1. Refer to Figure 2, and select the appropriate die
assembly and terminal or splice according to the wire.
For aluminum-to-aluminum application, butt splices
will accept the same wire size at either end.
For aluminum-to-copper application, the copper
wire size must be smaller to compensate for
differences in the electrical properties of copper
and aluminum. This also applies when using
copper wire in a terminal as listed in Figure 2.
2. Cut the end of the wire perpendicular to the wire;
DO NOT distort the shape of the wire. It is
recommended to chamfer the edge around the
group of wires. See Figure 2. The chamfer will aid in
the insertion of the wire into the terminal or splice.
3. Strip the wire to the length indicated in Figure 2.
DO NOT nick or cut the wire strands. The strip
length for the wire will depend on the number of
insulation layers covering the wire.
There are two approved methods for crimping the
terminals and splices using these die assemblies and
hydraulic crimping heads. Proceed as follows:
4.1. Terminal
IMPORTANT:
To ensure a quality crimp, gage the die
assembly at the beginning of a run, after changing a
die assembly — and then periodically during the run.
Refer to Paragraph 6.2 for gaging instructions.
CRIMPING DIE ASSEMBLY
HYDRAULIC CRIMPING HEAD
(Instruction Sheet)
68006
-0
68007
-0
68008
-0
68008-1
68009
-0
68010
-0
68010-2
314964-1
69066
-0
(408-2453)
58422-1 (408-9535)
1752787-1 (408-8914)
1752877-1 (408-8956)
1976441-1
1976442-1
1976443-1
59877-1
68011-1
314948-1
58422-1 (408-9535)
1752787-1 (408-8914)
Stationary Die
(Nest)
Alignment Dot
Front of
Die Assembly
Moving Die
(Anvil)
Shank
Shank
Alignment Dot
NOTE
i
!
CAUTION
!
CAUTION
DANGER
STOP
NOTE
i
O
R
IG
INAL
INST
RUCTIONS
