408-2281

CrimpingDie Assemblies for COPALUM Sealed Terminals and Splices

Rev W

4 of 9

Tyco Electronics Corporation

There are two approved methods for crimping the

connectors with this hydraulic tool, on both terminals

and splices.

To avoid personal injury, close the yoke of the

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.

3.1. Terminals

The preferred (first) method is:

1. Insert properly stripped wire fully into terminal.

DO NOT turn or twist the wire or terminal during

insertion.

2. Position terminal in stationary die (nest) with

back of tongue resting against die, with yoke

closed and pin inserted.

Make certain that the terminal is positioned so

that the crimper of the moving die (anvil) will

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.

Figure 3

Alignment

Dots

Pin

Yoke

Terminal Tongue

Rests Against

Side of Die

Crimper of Moving Die (Anvil)

Positioned to Crimp Wire

Barrel of Terminal (See

Figure 5 for Splice)

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.

Figure 4

Grip Terminal Between Die Assembly

and BreakAway Terminal Cutout When

Removing Terminal from Die Assembly

BreakAway

Terminal Cutout

Crimp Die

Assembly

If the terminal sticks in the die after crimping,

apply a rocking action to remove it from the die.

Wipe light oil or use spray dry lubricant on the

dies to prevent sticking.

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.

Make certain that the terminal is positioned so

that the crimper of the moving die (anvil) will

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.

DO NOT turn or twist the wire or terminal during

insertion.

4. Holding wire in place, with yoke closed and pin

inserted, activate power unit to complete crimp.

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.

If the terminal sticks in the die after crimping,

apply a rocking action to remove it from the die.

Wipe light oil or use spray dry lubricant on the

dies to prevent sticking.

DANGER

CAUTION

!

NOTE

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NOTE

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NOTE

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CAUTION

!

NOTE

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