408- 2353

Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts

Rev B

2

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 INJURY. 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 INJURY. 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

CMAD RANGE

WIRE STRIP LENGTH

CRIMPING

CRIMPING

WIRE

SIZE

CMAD RANGE

MIN

MAX

CRIMPING

DIE ASSY

CRIMPING

HEAD

8

6.638 -- 10.540

13,100 -- 20,800

10 32 [ 4062]

11 90 [ 4687]

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

69099

2

26.652 -- 42.412

52,600 -- 83,700

68046

69099

1752868--1

1/0

42.412 -- 60.55

83,700 -- 119,500

18 25 [ 7187]

19 84 [ 7812]

68047

1752868--1

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

69082

300 MCM

152.01 -- 192.55

300,000 -- 380,000

31.75 [1.250]

34.93 [1.375]

68035

69082

1752786--1

400 MCM

192.55 -- 242.20

380,000 -- 478,000

34.93 [1.375]

38.1 [1.50]

68036

1752786--1

500 MCM

242.20 -- 304.02

478,000 -- 600,000

38.1 [1.50]

41.28 [1.625]

68037

D

Circular 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

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