Instruction Sheet Crimping Die Assemblies for COPALUM* Sealed Terminals 408-2281 and Splices 12 NOV 20 REV CT Stationary Die Shank (Nest) Alignment Dot Moving Die (Anvil) Front of Die Assembly Alignment Dot Shank Figure 1 CRIMPING DIE HYDRAULIC HYDRAULIC CRIMPING HEAD ASSEMBLY CRIMPING HEAD (INSTRUCTION SHEET) 68006 68007 68008 58422-1 408-9535 68008-1 69066 408-2453 68009 1752787-1 408-8914 68010 1752877-1 408-8956 68010-1 68010-2 314964-1 59877-1 68011-1 314948-1 1976441-1 1976442-1 1976443-1 2217781-1 58422-1 408-9535 2217855-1 1752787-1 408-8914 2280034-1 2280035-1 2844065-1 2844065-2 2844425-2 2844430-1 2844430-2 Superseded by 68008-1 Superseded by 68010 Low Pressure Crimp Die Set Table 1 2020 TE Connectivity Ltd. family of companies. PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. 1 of 12 All Rights Reserved. For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS 408-2281 1. INTRODUCTION The crimping die assemblies are designed to be installed into the hydraulic crimping heads listed in Table 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. NOTE 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 die (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. DANGER 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 CAUTION 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. DANGER 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/Table 2 to select the appropriate die assembly and terminal or splice according to the wire. NOTE 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 Table 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/Table 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: 2 of 12 Rev CT