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68045

P1-P3P4-P6P7-P9P10-P12
408- 2353
Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts
7 of 12Rev B Tyco Electronics Corporation
4. CRIMP INSPECTION for COPALUM Terminals and
Splices (Figure 5A) and HF- 30 Pin and Socket Contacts
(Figure 5B)
Inspect crimped contacts by checking the features
described in Figure 5A or 5B as applicable. Use only
the terminals, splices, and contacts that meet the
conditions shown in the “ACCEPT” column.
“REJECT” terminals, splices, and contacts can be
avoided through careful use of the tabular information
in Figure 2A or 2B and the instructions Section 3, and
by performing regular die maintenance as instructed
in Section 5.
Figure 5A
(Crimp Inspection Criteria for COPALUM Terminals and Splices)
ACCEPT REJECT
Terminal
Parallel
Splice
Butt Splice
1
Crimps centered. Crimp may be slightly off center BUT
NOT OFF END OF WIRE BARREL.
2
CMA of wire being used matches wire range specified
for each terminal dash number.
3 Insulation does not enter wire barrel.
4
Wire is visible through inspection hole of butt splice,
and is flush with or extends slightly beyond end of
terminal wire barrel.
5
On parallel splices, bare wire ends must be flush with
or extend slightly beyond end of barrel.
1
Crimped off end of splice or terminal.
2
CMA of wire being used does not match wire range
stamped on terminal, splice, or dies.
3
Insulation entered barrel of terminal or splice. CHECK
FOR INCORRECT STRIP LENGTH.
4
Wire not inserted far enough in terminal or splice. End
of wire must be visible through inspection hole of butt
splices, and be flush with or extend slightly beyond
end of terminal wire barrel or parallel splice.
5
Excessive “flash” indicates wrong wire, terminal,
splice, or die combination was used.
6 Nicked or missing strands.
3
1
4
2
3
1
5
1
1
3
4
2
6
4
5
2
1
1
1
4
4
5
4
1
3
2
Wire Range
Stamped Here
Wire Range
Stamped Here
Wire Range
Stamped Here
Wire Range
Stamped Here
COPALUM Terminals and Splices
408- 2353
Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts
Rev B8 of 12 Tyco Electronics Corporation
Figure 5B
(Crimp Inspection Criteria for HF--30 Pin and Socket C ontacts)
ACCEPT
1
Crimps centered. Crimp may be slightly off center BUT
NOT OFF END OF WIRE BARREL.
3
Insulation does not enter wire barrel. No nicked,
missing, or broken wire strands.
7
6
Crimp die embossment, and wire size agree
with table in Figure 2. The verification of the
correct terminal dash number used with proper
crimp die and wire size must be done prior to
crimping of contacts. See Paragraph 3.5.1.
Crimp die embossment, and wire size agree
with table in Figure 2. The verification of the
correct terminal dash number used with proper
crimp die and wire size must be done prior to
crimping of contacts. See Paragraph 3.5.1.
1
3
6
7
3
33
1
Top View
Bottom View
Top View
Bottom View
Cutout for Housing Latch
Cutout for Housing Latch
Housing Stop
Cutout for Housing Latch
Cutout for Housing Latch
HF-30 Pin and Socket Contacts
408- 2353
Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts
9 of 12Rev B Tyco Electronics Corporation
5. MAINTENANCE/INSPECTION
AVOID PERSONAL INJURY; exercise extreme
caution when using power unit. Avoid depressing
foot switch or trigger control when installing or
removing die assemblies.
Customer--replaceable parts are listed in Figure 9.
A complete inventory should be stocked and
controlled to prevent lost time when replacement of
parts is necessary.
Crimping Die Assemblies are inspected before
shipment. Tyco Electronics recommends that the die
assembly be inspected immediately upon arrival at
your facility to ensure that it has not been damaged
during shipment.
5.1. Daily Maintenance
It is recommended that each operator of the tool be
made aware of -- and responsible for -- the following
three steps of daily maintenance:
1. Remove dust, moisture, 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.
Wipe excess oil from tool, particularly from
crimping area. Oil transferred from the crimping
area onto certain terminations may affect the
electrical characteristics of an application.
3. When the dies are not in use, mate them and
store the tool in a clean, dry area.
5.2. Periodic Inspection
T yco Electronics recommends that a maintenance
and inspection program be performed periodically to
ensure dependable and uniform terminations. Though
recommendations call for at least one inspection a
month, frequency of inspection depends on:
1. The care, amount of use, and handling of the
dies.
2. The presence of abnormal amounts of dust and
dirt.
3. The degree of operator skill.
4. Your own established standards.
A. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the die assembly in a suitable
commercial degreaser that will not affect paint or
plastic material.
2. Inspect the crimp area for flattened, chipped,
cracked, worn, or broken areas. If damage is
evident, the dies must be replaced or repaired.
Examples of possible damaged die closure
surfaces are shown in Figure 6. If desired, you
may return them to Tyco Electronics for evaluation
and repair (see Section 6, REPAIR).
Figure 6
Pitted
Broken Corner
B. Gaging the Crimping Chamber
This inspection requires the use of a plug gage
conforming to the diameters provided in Figure 7.
T yco Electronics does not manufacture or market
these gages. The following procedure is
recommended for inspecting the die closures.
1. Clean oil or dirt from the die closure areas, and
plug gage elements.
2. Assemble and adjust dies to meet the “gage
dimension” indicated in Figure 8, Detail A.
3. With dies positioned at the “gage dimension,”
inspect the bar crimp closure using the proper plug
gage. 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 8,
Detail A.
4. 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 through, as shown in Figure 8,
Detail A.
5. With dies positioned at “gage dimension,” check
the right and left rectangular crimp closures using
the proper plug gage in the same manner as Steps
4 and 5; see Figure 8, Detail B.
DANGER
NOTE
i
P1-P3P4-P6P7-P9P10-P12

68045

Mfr. #:
Buy 68045
Manufacturer:
TE Connectivity
Description:
DIE COPALUM 4 69099
Lifecycle:
New from this manufacturer.
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