408-2281

Crimping Die Assemblies for COPALUM Sealed Terminals and Splices

5 of 9

Rev W

Tyco Electronics Corporation

3.2. Splices

The preferred (first) method is:

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.

1. Insert properly stripped wire fully into splice.

DO NOT turn or twist the wire or splice during

insertion.

Make sure that the splice is properly aligned in

the stationary die so that moving die will crimp

the wire barrel of the splice.

2. Position splice in die assembly so that edge of

die is within width of splice crimp mark. The stripe

marking on splice must be inside die, facing up,

and in alignment with dot on nest. See Figure 5.

When crimping a splice with a color coded band

around the end of the splice, use the correct

copper conductors in the color coded end of the

splice.

3. Holding wire in place, activate power unit to

complete first splice crimp.

4. When crimp is completed, remove pin, open

yoke, and remove splice.

If the splice sticks in 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

reduce sticking.

5. To crimp other half of splice, rotate the

splice/tool 180

_, making sure the stripe marking on

the splice is inside the assembly, facing up, and in

alignment with dot on nest. See Figure 5. Follow

the same procedure used to crimp first side of

splice (steps 1 through 4).

The alternate (second) method is slightly different, but

very important. The difference is in preceding Step 1.

1. Position splice in die assembly so that edge of

die is within width of splice crimp mark. The stripe

marking on splice must be inside die, facing up,

and in alignment with dot on nest. See Figure 5.

2. Do NOT insert wire into splice, instead, jog to

advance the ram to hold the splice. This is difficult

to do; If the splice is deformed, the wire may not be

inserted properly.

3. Insert properly stripped wire fully into splice wire

barrel.

Stripe Marking Must

Be on Top

Figure 5

Anvil

Nest

Edge of Die Positioned

Within Width of Splice

Crimp Mark

Splice Crimp Marks

Anvil

Wire

Pin

Stripe Marking

on Top

Dot

Nest

Splice Detail

View

DO NOT turn or twist the wire or splice during

insertion.

When crimping a splice with a color coded band

around the end of the splice, use the correct

copper conductors in the color coded end of the

splice.

4. Holding wire in place, activate power unit again

to complete crimp.

5. When crimp is completed, remove pin, open

yoke, and remove splice.

If the splice sticks in 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

reduce sticking.

6. To crimp other half of splice, rotate the

splice/tool 180

_, making sure the stripe marking on

splice is inside the assembly, facing up, and in

alignment with dot on nest. See Figure 5. Follow

the same procedure used to crimp first side of

splice (Steps 1 through 5).

DANGER

CAUTION

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CAUTION

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