Instruction Sheet
Crimping Die Assemblies for
COPALUM* Sealed Terminals and Splices
2. DESCRIPTION
Nest
(Stationary Die)
408-2281
21 NOV 08
Rev W
(Figure 1)
The die assemblies consist of stationary dies (nests)
and moving dies (anvils). Refer to Figure 2 to ensure
the compatibility of die assemblies, crimping heads,
and terminals and splices.
Alignment
Dot
2.1. Die Installation
DANGER
To avoid personal injury, ALWAYS DISCONNECT
electrical and air supply to power unit before
installing dies.
Alignment
Dot
Front
Anvil
(Moving Die)
CRIMPING DIE ASSEMBLY
CRIMPING HEAD
068006-00
068007-0
69066
068008-00
068009-0
0058422-1
068010-00
068010-2
1752787-1
0314964-1
68008-1
1752877-1
1976441-1
059877-1
1976442-1
068011-1
1976443-1
314948-1
0058422-1
1752787-1
The shanks on the moving and stationary dies are
offset, and there are alignment dots on the FRONT
surface of the dies. The shanks of the dies must be
offset to the same surface and the dots must be
aligned, and face the operator, in order to achieve
proper mating of the dies.
CAUTION
DO NOT mix die components from different die
assemblies.
!
Refer to Instruction Sheet 408–9535 for die
installation procedure for Crimping Head 58422–1;
408–2453 for Crimping Head 69066; 408–8914
for Crimping Head 1752787–1; and 408–8956 for
Crimping Head 1752877–1.
Figure 1
2.2. Wire, Terminal, and Splice Selection
1. INTRODUCTION
The crimping die assemblies listed in Figure 1 are
used to crimp COPALUM sealed terminals and
splices.
The crimping die assemblies must be installed into
the crimping heads shown in Figure 1. Refer to the
instruction sheet packaged with the crimping head for
information concerning die installation and general
performance of the head.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
Read these instructions thoroughly before using the
die assemblies.
(Figure 2)
Refer to Figure 2 and select the appropriate wire, die
assembly, and terminal or splice. Strip the wire to the
length indicated in the table.
CAUTION
DO NOT nick or cut the wire strands.
!
NOTE
For aluminum-to-aluminum application, butt
splices will accept the same wire size at either
i
end. However, for aluminum-to-copper
applications, the size of the copper wire must be
decreased to a smaller size to compensate for
differences in the electrical properties of copper
NOTE
i
Dimensions in this instruction sheet are in
and aluminum. It is also necessary to use a
millimeters [with inches in brackets]. Figures and
smaller wire size when using copper wire in a
illustrations are for reference only and are not
terminal. Refer to CMA range listed with each
drawn to scale.
wire size in Figure 2.
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
1 of 9
LOC B
408-2281
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
Ring-Tongue Terminal
Wire Strip Length
1
Butt Splice (BS)
(RT) Single Hole
+1.59 [+ /16 ]
C"
C"
B"
B"
A"
D"
C"
Ring-Tongue Terminal
B"
(RT) Two Hole
4 Layers of
2 Layers of
Insulation
Insulation
Transitional Butt
Splice (TS)
D"
C"
B"
Aluminum
Side
B" Equals Wire Barrel
C" Equals Insulation Barrel
Copper
Side
1 or 2 Layers
of Insulation
Blue Ink Ring
TERMINALS (RT)
BUTT
SINGLE
DOUBLE
HOLE
HOLE
277147-[ ]
Ċ
277148-[ ]
277149-[ ]
277150-[ ]
277151-[ ]
227152 [ ]
227152-[
277153-[ ]
Ċ
(BS)
277156-[ ]
55832-[ ]
55833-[ ]
55834-[ ]
55835-[ ]
55836-[ ]
55837-[ ]
55838-[ ]
55839-[[ ]
55844-[ ]
277157-[ ]
s
277158-[ ]
s
277159-[ ]
s
277160-[ ]
s
277161 [ ]
277161-[
55840-[ ]
55841-[ ]
SPLICES
277162-[ ]
s
Ċ
ALUMINUM WIRE
2
mm
(CMA)
F Y
8.60
(16,564)
14.60
(28,280)
21.90
(42,420)
35.00
(67,872)
55.50
(107,464)
71.30
(138,168)
87.20
(168,872)
110.94
(214,928)
AWG
8
6
4
2
1/0
2/0
3/0
4/0
COPPER WIRE
2
mm
(CMA)
F
4.80
(9,354)
8.80
(16,983)
13.80
(26,818)
22.00
(42,615)
34.30
(66,500)
53.90
(104,500)
68.60
(133,000)
85.94
(166,500)
STRIP LENGTH
DIE
J
AWG
10
8
6
4
2
1/0
2/0
3/0
DIM. A
DIM. D
(Insulation)
(Conductor)
22.23
11.11
7
7
[ /8]
[ /16]
22.23
12.70
7
1
[ /8]
25.40
[1]
[ /2]
17.45
11
[
/16]
31.75
19.10
[1 /4]
1
[ /4]
32.54
25.40
3
9
[1 /32]
[1]
34.93
25.40
[1 /8]
3
[1]
34.93
25.40
[1 /8]
3
[1]
33.34
25.40
5
[1 /16]
[1]
32.54
25.40
ASSEMBLY
HEAD
68006
68007
68008
68008-1
0058422-1
0069066-0
1752787 1
1752787-1
68009
1752877-1
68010
314964-1
68011-1
59877-1
0058422-1
1752787-1
1752787
1
314948-1
TRANSITIONAL BUTT SPLICES (TS)
277163-[ ]
277164-[ ]
277165-[ ]
277168-[ ]
55.50
(107,464)
21.90
(42,420)
21.90
(42,420)
87.20
(168,872)
1/0
4
4
3/0
22.00
(42,615)
8.80
(16,983)
22.00
(42,615)
53.90
(104,500)
4
8
4
1/0
9
[1 /32]
[1]
25.40
17.45
[1]
25.40
[1]
11
[
/16]
17.45
11
[
/16]
34.93
25.40
3
[1]
[1 /8]
68010
0058422-1
68008-1
68008
0069066-0
1752787-1
1752877 1
1752877-1
68008-1
59877-1
0058422-1
1752787-1
F Circular Mill Area Y See MIL–W–7072 for Specific Wire Requirements
J See MIL–W–22759E for Specific Wire Requirements s High Temperature Silver Plated
Figure 2 (Cont’d)
2 of 9
Tyco Electronics Corporation
Rev W
408-2281
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
TERMINALS AND SPLICES FOR USE WITH BOEING BMS13-78 WIRE
ALUMINUM
TERMINALS (RT)
BUTT
SPLICES
SINGLE
DOUBLE
HOLE
HOLE
(BS)
WIRE
2
mm
(CMA)
F Y
AWG
COPPER WIRE
2
mm
(CMA)
{
F J
STRIP LENGTH
DIE
AWG
DIM. A
DIM. D
(Insulation)
(Conductor)
'
ASSEMBLY
HEAD
'
z
z
z
'
'
'
'
'
'
TERMINALS FOR USE WITH NEXANS ALUMINUM WIRE
TERMINALS (RT)
3
/8 STUD
3
/8 STUD
DOUBLE
HOLE
ALUMINUM WIRE
3
/8 STUD,
15
° BEND
2
mm
STRIP LENGTH
DIE
F
AWG
(CMA)
Y
DIM. A
DIM. D
(Insulation)
(Insulation)
ASSEMBLY
'
'
'
'
HEAD
CRN TERMINALS
ALUMINUM
STRAIGHT
90
° BEND
WIRE
2
mm
(CMA)
COPPER WIRE
STRIP LENGTH
DIE
F Y
AWG
2
mm
(CMA)
F J
AWG
DIM. A
DIM. D
(Insulation)
(Insulation)
ASSEMBLY
HEAD
{ Only Applies to Splices (Not Terminals) F Circular Mill Area Y See MIL–W–7072 for Specific Wire Requirements
J See MIL–W–22759E for Specific Wire Requirements z Break Away Terminal
Figure 2 (End)
$ W
% #!" ! !#
3 408-2281
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
3. CRIMPING PROCEDURE (Figures 3, 4, and 5)
There are two approved methods for crimping the
connectors with this hydraulic tool, on both terminals
and splices.
DANGER
4. Remove crimped terminal from the die
assembly. Refer to Figure 4 on where to grip
breakaway terminals when removing them from the
die assembly.
To avoid personal injury, close the yoke of the
Grip Terminal Between Die Assembly
hydraulic head and fully insert the pin. When
and Break Away Terminal Cutout When
Removing Terminal from Die Assembly
operating the power unit, be careful when
handling terminals, splices, or wire near the
Crimp Die
Assembly
crimping area of the crimping head.
3.1. Terminals
The preferred (first) method is:
1. Insert properly stripped wire fully into terminal.
CAUTION
DO NOT turn or twist the wire or terminal during
insertion.
Break Away
Terminal Cutout
!
Figure 4
2. Position terminal in stationary die (nest) with
back of tongue resting against die, with yoke
closed and pin inserted.
NOTE
Make certain that the terminal is positioned so
NOTE
If the terminal sticks in the die after crimping,
apply a rocking action to remove it from the die.
i
Wipe light oil or use spray dry lubricant on the
dies to prevent sticking.
that the crimper of the moving die (anvil) will
i
crimp wire barrel of the terminal. See Figure 3.
3. Holding wire in place, and fully inserted (yoke
closed and pin fully inserted), activate power unit to
complete crimp.
The alternate (second) method is:
1. Position terminal in stationary die (nest) with
back of tongue resting against die, with yoke
closed and pin inserted.
NOTE
Make certain that the terminal is positioned so
that the crimper of the moving die (anvil) will
i
Yoke
Terminal Tongue
Alignment
Rests Against
Dots
Side of Die
crimp the wire barrel of the terminal. See
Figure 3.
2. The wire is not inserted into the terminal.
Instead, Jog to advance the ram to hold the
terminal. This is difficult to do; If the terminal barrel
is deformed, the wire may not be inserted properly.
3. Insert properly stripped wire fully into terminal.
CAUTION
DO NOT turn or twist the wire or terminal during
insertion.
!
Pin
4. Holding wire in place, with yoke closed and pin
inserted, activate power unit to complete crimp.
Crimper of Moving Die (Anvil)
Positioned to Crimp Wire
5. Remove crimped terminal from the die
assembly. See Figure 4 for information on where to
grip break away terminals when removing them
from the die assembly.
Barrel of Terminal (See
Figure 5 for Splice)
NOTE
If the terminal sticks in the die after crimping,
apply a rocking action to remove it from the die.
Figure 3
4 of 9
i
Tyco Electronics Corporation
Wipe light oil or use spray dry lubricant on the
dies to prevent sticking.
Rev
W
408-2281
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
3.2. Splices
Stripe Marking Must
Be on Top
The preferred (first) method is:
DANGER
To avoid personal injury, close the yoke of the
Edge of Die Positioned
Within Width of Splice
Crimp Mark
Nest
hydraulic 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 crimping head.
Splice Crimp Marks
1. Insert properly stripped wire fully into splice.
CAUTION
DO NOT turn or twist the wire or splice during
Anvil
insertion.
!
Dot
Splice Detail
NOTE
View
Make sure that the splice is properly aligned in
Nest
the stationary die so that moving die will crimp
i
the wire barrel of the splice.
Wire
2. Position splice in die assembly so that edge of
die is within width of splice crimp mark. The stripe
marking on splice must be inside die, facing up,
and in alignment with dot on nest. See Figure 5.
NOTE
Pin
When crimping a splice with a color coded band
around the end of the splice, use the correct
i
copper conductors in the color coded end of the
splice.
Stripe Marking
on Top
3. Holding wire in place, activate power unit to
complete first splice crimp.
4. When crimp is completed, remove pin, open
yoke, and remove splice.
NOTE
If the splice sticks in die after crimping, apply a
Figure 5
CAUTION
rocking action to remove it from the die. Wipe
i
light oil or use spray dry lubricant on the dies to
reduce sticking.
5. To crimp other half of splice, rotate the
splice/tool 180_, making sure the stripe marking on
the splice is inside the assembly, facing up, and in
alignment with dot on nest. See Figure 5. Follow
the same procedure used to crimp first side of
splice (steps 1 through 4).
The alternate (second) method is slightly different, but
very important. The difference is in preceding Step 1.
1. Position splice in die assembly so that edge of
die is within width of splice crimp mark. The stripe
marking on splice must be inside die, facing up,
and in alignment with dot on nest. See Figure 5.
2. Do NOT insert wire into splice, instead, jog to
advance the ram to hold the splice. This is difficult
to do; If the splice is deformed, the wire may not be
inserted properly.
3. Insert properly stripped wire fully into splice wire
barrel.
Rev W
Anvil
DO NOT turn or twist the wire or splice during
insertion.
!
NOTE
When crimping a splice with a color coded band
around the end of the splice, use the correct
i
copper conductors in the color coded end of the
splice.
4. Holding wire in place, activate power unit again
to complete crimp.
5. When crimp is completed, remove pin, open
yoke, and remove splice.
NOTE
If the splice sticks in die after crimping, apply a
rocking action to remove it from the die. Wipe
i
light oil or use spray dry lubricant on the dies to
reduce sticking.
6. To crimp other half of splice, rotate the
splice/tool 180_, making sure the stripe marking on
splice is inside the assembly, facing up, and in
alignment with dot on nest. See Figure 5. Follow
the same procedure used to crimp first side of
splice (Steps 1 through 5).
Tyco Electronics Corporation
5 of 9
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
4. CRIMP INSPECTION
A crimp inspection mark is featured on each crimped
terminal or splice. The mark consists of a dimple on
the face of a cylinder which is embossed in the
primary crimp area of the terminal or splice. The
inspection mark must appear as shown in Application
Specification 114–2134.
The inspection mark must appear as indicated in
114–2134, in order to qualify the terminal or splice as
an acceptable termination. The terminal or splice is
unacceptable and should be rejected if the
identification mark is deformed.
If the mark is deformed, refer to Figure 2 to verify
proper wire CMA and terminal and die combination.
Verify that crimping dies fully bottom during crimp
cycle. Also, determine if dies are in proper
configuration by gaging the crimp chamber specified
in Paragraph 5.2.B.
5. MAINTENANCE AND INSPECTION
DANGER
supervisory personnel responsible for the dies.
Though 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. These inspections should be
performed in the following sequence:
A. Visual Inspection
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 dies must be replaced or repaired. If
desired, you may return them for evaluation and
repair (see Section 6, REPLACEMENT AND
REPAIR).
B. Gaging the Crimping Chamber
To avoid personal injury, ALWAYS DISCONNECT
electrical and air supply to power unit before
performing adjustments, inspections, or repairs.
Die assemblies are inspected before shipment. It is
recommended that the die assembly be inspected
immediately upon arrival at your facility to ensure that
it conforms to the dimensions provided in Figure 7,
and that it has not been damaged during shipment.
This inspection requires the use of a plug gage
conforming to the measurements provided in Figure
6. Gages may be purchased from:
Pennoyer–Dodge Company
6634–T San Fernando Road
Glendale, CA 91201
Proceed as follows:
1. Mate the dies until it is evident that they have
bottomed. Hold the dies in this position.
5.1. Daily Maintenance
It is recommended that each operator of the dies be
made aware of — and responsible for — the following
three steps of daily maintenance.
1. Remove dust, dirt, and other contaminants with
a clean brush, or a soft, lint–free cloth. DO NOT
use objects that could damage the dies.
2. Make certain the dies are protected with a thin
coat of any good SAE 20 motor oil. DO NOT OIL
EXCESSIVELY.
3. When the dies are not in use, mate them and
store in a clean dry area.
5.2. 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
6 of 9
408-2281
2. Align the GO element of the gage with the
crimping chamber. Push the element straight into
the chamber without using force. The GO element
must pass completely through the crimping
chamber without using force as shown in Figure 6.
3. Align the NO–GO element with the crimping
chamber and try to insert it straight into the
chamber. The NO–GO element may start entry but
must not pass completely through, as shown in
Figure 6.
If the crimping chamber conforms to the gage
inspection, the dies are considered dimensionally
correct and should be lubricated with a thin coat of
any good SAE 20 motor oil. If not, the dies must be
replaced or repaired before returning them to service.
For additional information concerning the use of the
plug gage, refer to Instruction Sheet 408–7424.
Tyco Electronics Corporation
Rev W
408-2281
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
Inspection of Wire Barrel Crimping Chamber
GO" Gage Element Must Pass
Completely Through Crimping Chamber
Dies are Bottomed but
Not Under Pressure
Plug Gage
NO-GO" Gage Element May Enter
Partially, but Must Not Pass Completely
Through Crimping Chamber
Die Closure
Configuration
Suggested Plug Gage Design Ċ Wire Barrel Crimping Chamber
GO Dim.
B
NO-GO Dim.
C
B
R
25.4 [1.00] Min. Typ
DIE
ASSEMBLY
GAGE ELEMENT DIM. B
GO
NO-GO
DIM C
DIM.
R" ((Radius))
(Max)
0059877-1
7.518-7.526 [.2960-.2963]
7.769-7.772 [.3059-.3060]
9.91 [.390]
7.62 [.300]
0068006-0
2.870-2.877 [.1130-.1133]
3.045-3.048 [.1199-.1200]
6.35 [.250]
3.16 [.125]
0068007-0
3.200-3.208 [.1260-.1263]
3.375-3.378 [.1329-.1330]
6.35 [.250]
3.556 [.140]
3.937-3.944 [.1550-.1553]
4.112-4.114 [.1619-.1620]
6.35 [.250]
4.34 [.171]
0068009-0
5.003-5.011 [.1970-.1973]
5.179-5.181 [.2039-.2040]
9.91 [.390]
5.54 [.218]
0068010-0
6.197-6.205 [.2440-.2443]
6.372-6.375 [.2509-.2510]
9.91 [.390]
6.73 [.265]
0068010-2
6.579-6.586 [.2590-.2593]
6.754-6.756 [.2659-.2660]
9.91 [.390]
6.73 [.265]
0068011-1
7.924-7.932 [.3120-.3123]
8.100-8.102 [.3189-.3190]
9.91 [.390]
7.52 [.296]
0314948-1
9.550-9.558 [.3760-.3763]
9.802-9.804 [.3859-.3860]
9.91 [.390]
8.13 [.320]
0314964-1
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]
0068008
68008-1
Figure 6 (Cont’d)
Rev
W
Tyco Electronics Corporation
7 of 9
408-2281
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
Inspection of Insulation Sealing Crimping Chamber
GO" Gage Element Must Pass
Completely Through Crimping Chamber
Dies are Bottomed but
Not Under Pressure
Plug Gage
NO-GO" Gage Element May Enter
Partially, but Must Not Pass Completely
Through Crimping Chamber
Suggested Plug Gage Design Ċ Insulation Sealing Crimping Chamber
Die Closure
Configuration
GO Dim.
E
NO-GO Dim.
E
W
R
25.4 [1.00] Min Typ
DIE
ASSEMBLY
GAGE ELEMENT DIM. E
NO-GO
GO
DIM. W
(Max)
R" (Radius)
(
)
(Max)
0059877-1
16.205-16.213 [.6380-.6383]
16.609-16.612 [.6539-.6540]
16.15 [.636]
8.08 [.318]
0068006-0
6.248-6.256 [.2460-.2463]
6.652-6.665 [.2619-.2620]
6.20 [.244]
3.10 [.122]
0068007-0
7.518-7.526 [.2960-.2963]
7.922-7.925 [.3119-.3120]
7.47 [.294]
3.73 [.147]
9.195-9.202 [.3620-.3623]
9.599-9.601 [.3779-.3780]
9.14 [.360]
4.57 [.180]
11.379-11.387 [.4480-.4483]
11.783-11.786 [.4639-.4640]
11.33 [.446]
5.66 [.223]
13.818-13.825 [.5440-.5443]
14.221-14.224 [.5599-.5600]
13.77 [.542]
6.88 [.271]
0068011-1
15.037-15.044 [.5920-.5923]
15.441-15.443 [.6079-.6080]
14.99 [.590]
7.49 [.295]
0314948-1
16.205-16.213 [.6380-.6383]
16.609-16.612 [.6539-.6540]
16.15 [.636]
8.08 [.318]
0314964-1
15.037-15.044 [.5920-.5923]
15.441-15.443 [.6079-.6080]
14.99 [.590]
7.49 [.295]
1976441-1
15.037-15.044 [.5920-.5923]
15.441-15.443 [.6079-.6080]
14.99 [.590]
7.49 [.295]
1976442-1
16.205-16.213 [.6380-.6383]
16.609-16.612 [.6539-.6540]
16.15 [.636]
8.08 [.318]
1976443-1
16.205-16.213 [.6380-.6383]
16.609-16.612 [.6539-.6540]
16.15 [.636]
8.08 [.318]
0068008
68008-1
0068009-0
0068010-0
0068010-2
Figure 6 (End)
6. REPLACEMENT AND REPAIR
or write to:
Parts listed in Figure 7 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
representative, or call 1–800–526–5142, or send a
facsimile of your purchase order to 1–717–986–7605,
8 of 9
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG, PA 17105–3608
Dies may also be returned for evaluation and repair.
For die repair service, call 1–800–526–5136.
Tyco Electronics Corporation
Rev
W
408-2281
Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
2
Nest
(1 Per Die Assembly)
Anvil
108 [4.25]
1
(1 Per Die Assembly)
Weight: 255 g [9 oz]
44.50 [1.75]
51 [2.00]
REPLACEMENT PARTS
ITEM
DIE ASSEMBLY
59877-1
68006
68007
68008
68009
68010
68010-2
68011-1
314948-1
314964-1
1
312309-9
312309-1
312309-2
312309-3
312309-4
1-312309-0
1-312309-1
312309-7
314951-1
314965-1
2
307465-9
307465-1
307465-2
307465-3
307465-4
307465-5
307465-5
307465-7
307465-9
307465-7
ITEM
DIE ASSEMBLY
1976441-1
1976442-1
1976443-1
68008-1
1
1-312309-2
1-312309-3
314951-2
1-312309-4
2
1-307465-1
1-307465-2
1-307465-2
1-307465-3
Figure 7
7. REVISION SUMMARY
Revisions to this instruction sheet include:
S Updated document to corporate requirements
S Added part number 68008–1 in tables in
Figures 1, 2, 6, and 7
Rev
W
Tyco Electronics Corporation
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