408- 2353
Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts
Rev B2 of 12 Tyco Electronics Corporation
2. Insert shank of stationary die into top section of
crimping head and tighten retaining screw.
Ensure that the dies are inserted fully and that
the “flats” on shanks are facing the operator.
3. Activate power unit to advance ram until
setscrew is visible.
AVOID PERSONAL I NJURY. Exercise extreme
caution when using power unit. Avoid depressing
foot switch or trigger control when installing or
removing die assemblies.
4. Loosen setscrew and insert shank of moving die
into ram well. Tighten setscrew.
5. Activate power unit to complete cycle and allow
ram to return to down position.
2.2. Die Removal
1. Loosen retaining screw in top section of
crimping head and remove die.
2. Raise ram to full up position. Loosen setscrew in
ram and remove die.
AVOID PERSONAL I NJURY. Exercise extreme
caution when using power unit. Avoid depressing
foot switch or trigger control when installing or
removing die assemblies.
3. WIRE STRIPPING AND CRIMPING PROCEDURE
3.1. Wire Stripping Procedure
1. Select the proper size terminal, splice, or HF--30
pin and socket contact for the wire size being used.
See Figure 2A for COPALUM Terminal and Splices
or Figure 2B for HF--30 Pin and Socket Contacts.
2. StripwiretodimensionindicatedinFigure2A
for COPALUM Terminals and Splices or Figure 2B
for HF--30 Pin and Socket Contacts.
Do NOT nick or cut conductor strands. When
stripping wires for HF--30 Pin and Socket
Contacts, be sure to remove clear plastic
insulation material from conductors prior
to
crimping
.
3.2. Crimping COPALUM Terminals
AVOID PERSONAL INJURY; when operating
power unit, exercise caution while holding
terminals or wire near crimping area. Never place
anything within the crimping dies except
COPALUM terminals and splices and HF--30 pin
and socket contacts.
1. Ensure that the wire size stamped on the
terminal corresponds with the size marked on the
dies.
2. Center terminal wire barrel in stationary die.
Terminals may be crimped with tongue facing
either die. (Tyco Electronics recommends the
terminal positioning shown in Figure 3:) (tongue
toward moving die.)
Depending on conductor hardness, and if near
maximum conductor CMA limit is reached, some
cracking may occur in crimp area when terminal
is crimped with tongue toward stationary die.
WIRE
WIRE STRIP LENGTH
CRIMPING CRIMPING
SIZE
mm
MAD RAN
E
MIN MAX
DIE ASSY
HEAD
8 6.638 -- 10.540 13,100 -- 20,800
68043
6 10.540 -- 16.772 20,800 -- 33,100
10.32
.4062
11.90
.4687
68044
4 16.772 -- 26.652 33,100 -- 52,600 14.29 [.5625] 15.88 [.6250] 68045
2 26.652 -- 42.412 52,600 -- 83,700 68046
69099
--
1/0 42.412 -- 60.55 83,700 -- 119,500
68047
--
2/0 60.55 -- 76.26 119500 -- 150,500
18.25
.7187
19.84
.7812
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
300 MCM 152.01 -- 192.55 300,000 -- 380,000 31.75 [1.250] 34.93 [1.375] 68035
69082
--
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)
NOTE
i
DANGER
DANGER
CAUTION
!
DANGER
NOTE
i
