Instruction Sheet
CrimpingDieAssembliesfor
COPALUM*TerminalsandSplices
408--2353
andHF-30PinandSocketContacts 25 MAR 10 Rev B
Crimping Head (Ref)
Tool Head
Radii
Retaining Screw
Stationary Die (Nest)
Die Radii
Setscrew
in Ram
CRIMPING DIESUSED IN ...
CRIMPINGHEAD CRIMPINGHEAD
69082,1752786--1 69099,1752868--1
68043 68044 68045
68034 68035 68036
68046 68047 Moving Die
Flats on Shank
68037 68037--1 68050
68048 68049
(Indenter)
Figure 1
aluminum or copper{ wire and HF--30 Pin and Socket
1. INTRODUCTION
Contacts for stranded aluminum and copper wire
This instruction sheet covers the use of Crimping Die
sizes specified in Figure 2B.
AssemblieslistedinFigure1,whichareusedtocrimp
Dies are coated with preservative to prevent rust and
COPALUM Terminals and Splices and HF--30 Pin and
corrosion. Wipe this preservative away from dies,
Socket Contacts. The die assemblies are used in
particularly from crimping areas.
Crimping Heads 69082, 69099, 1752786--1, and
1752868--1. Refer to instruction sheet packaged with
For further instructions on the hydraulic power unit
the crimping head for information concerning die
and hydraulic crimping heads, refer to the instructions
installation and general performance of the head.
packaged with these tools.
Read these instructions thoroughly before using the
die assemblies.
2.1. DieInstallation
See Section 7, REVISION SUMMARY, for revision
AVOID PERSONAL INJURY. Exercise extreme
DANGER
information.
caution when using power unit. Avoid depressing
foot switch or trigger control when installing or
All dimensions on this document are in metric
NOTE
removing die assemblies. DO NOT MIX DIE
units [with U.S. customary units in brackets].
COMPONENTS FROM DIFFERENT DIE SETS.
Figures and illustrations are for reference only
i
and are not drawn to scale.
The radii of both dies must match the radii of the tool.
SeeFigure1.
2. DESCRIPTION
Crimping head No. 69099 is illustrated throughout this
publication; however, die insertion, die removal and
The die assemblies consist of stationary dies (nest)
crimping instructions are the same for 69099, 69082,
and moving dies (indenter). Refer to Figure 2A
1752786--1, and 1752868--1 crimping heads.
(COPALUM contacts) or Figure 2B (HF--30 Contacts)
to ensure the compatibility of die assemblies,
Proceed as follows:
crimping heads, and terminals and splices. These
dies are used to crimp COPALUM Terminals and 1. Loosen retaining screw in top section of
Splices on No. 8 through 500 MCM stranded or solid, crimping head. See Figure 1.
{Butt Splices Only. Referto Paragraph 3.3
E2010 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlled document is subject to change.
1 of 12
PRODUCT INFORMATION 1--800--522--6752 Forlatest revision and Regional CustomerService,
All Rights Reserved
visit ourwebsite atwww.tycoelectronics.com
TE logo and Tyco Electronics are trademarks.
LOC B
*Trademark. Otherproduct names, logos, orcompany names might be trademarks of theirrespective owners.408-2353
DieAssembliesforCOPALUMTerminalsandSplicesandHF-30PinandSocketContacts
2. Insert shank of stationary die into top section of See Figure 2A for COPALUM Terminal and Splices
crimping head and tighten retaining screw. or Figure 2B for HF--30 Pin and Socket Contacts.
Ensure that the dies are inserted fully and that
NOTE
2.StripwiretodimensionindicatedinFigure2A
the flats on shanks are facing the operator.
for COPALUM Terminals and Splices or Figure 2B
i
for HF--30 Pin and Socket Contacts.
3. Activate power unit to advance ram until
setscrew is visible.
Do NOT nick or cut conductor strands. When
CAUTION
stripping wires for HF--30 Pin and Socket
DANGER
AVOID PERSONAL INJURY. Exercise extreme
Contacts, be sure to remove clear plastic
caution when using power unit. Avoid depressing
!
insulation material from conductors prior to
foot switch or trigger control when installing or
crimping.
removing die assemblies.
4. Loosen setscrew and insert shank of moving die
3.2. CrimpingCOPALUMTerminals
into ram well. Tighten setscrew.
5. Activate power unit to complete cycle and allow
DANGER
AVOID PERSONAL INJURY; when operating
ram to return to down position.
power unit, exercise caution while holding
terminals or wire near crimping area. Never place
2.2. DieRemoval
anything within the crimping dies except
COPALUM terminals and splices and HF--30 pin
1. Loosen retaining screw in top section of
and socket contacts.
crimping head and remove die.
1. Ensure that the wire size stamped on the
2. Raise ram to full up position. Loosen setscrew in
terminal corresponds with the size marked on the
ram and remove die.
dies.
AVOID PERSONAL INJURY. Exercise extreme
DANGER
2. Center terminal wire barrel in stationary die.
caution when using power unit. Avoid depressing
Terminals may be crimped with tongue facing
foot switch or trigger control when installing or
either die. (Tyco Electronics recommends the
removing die assemblies.
terminal positioning shown in Figure 3:) (tongue
toward moving die.)
3. WIRESTRIPPINGANDCRIMPINGPROCEDURE
NOTE
Depending on conductor hardness, and if near
3.1. WireStrippingProcedure
maximum conductor CMA limit is reached, some
1. Select the proper size terminal, splice, or HF--30 cracking may occur in crimp area when terminal
i
pin and socket contact for the wire size being used. is crimped with tongue toward stationary die.
WIRESTRIPLENGTH
WWIRIREE CRICRIMMPPIINNGG CCRIRIMMPPIINNGG
22
mmmm CCMMAADDRANRANGGEE
SIZE DIEASSY HEAD
MIN MAX
8 6.638 -- 10.540 13,100 -- 20,800 68043
110.320 32 [[.40624062]] 1111.9900 [[.46874687]]
6 10.540 -- 16.772 20,800 -- 33,100 68044
4 16.772 -- 26.652 33,100 -- 52,600 14.29 [.5625] 15.88 [.6250] 68045
6909969099
2 26.652 -- 42.412 52,600 -- 83,700 68046
11775522886688----11
1/0 42.412 -- 60.55 83,700 -- 119,500 68047
118.258 25 [[.71877187]] 119.849 84 [[.78127812]]
2/0 60.55 -- 76.26 119500 -- 150,500 68048
3/0 76.26 -- 96.27 150,500 -- 190,000 68049
4/0 96.27 -- 117.049 190,000 -- 231,000 19.10 [.75] 20.64 [.8125] 68050
250 MCM 117.049 -- 152.01 231.000 -- 300,000 28.58 [1.125] 31.75 1.250 68034
6690829082
300 MCM 152.01 -- 192.55 300,000 -- 380,000 31.75 [1.250] 34.93 [1.375] 68035
11775522778866----11
400 MCM 192.55 -- 242.20 380,000 -- 478,000 34.93 [1.375] 38.1 [1.50] 68036
500 MCM 242.20 -- 304.02 478,000 -- 600,000 38.1 [1.50] 41.28 [1.625] 68037
DCircular Mil Area Figure 2A
(For Crimping COPALUM Terminals and Splices -- See Paragraphs 3.2, 3.3, and 3.4)
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