Instruction Sheet
Crimping Die Assembly 318106-1
408-4199
for Insulation Piercing
COPALUM* Terminals and Splices
12 DEC 07
Rev A
Crimping
Head (Ref)
Tool Head
Radii
Retaining
Screw
Stationary Die
(Indenter)
Die Radii
Setscrew
in Ram
Flats on
Moving
Shank
Die (Anvil)
Figure 1
1. INTRODUCTION
NOTE
This instruction sheet covers the application and
maintenance procedures for Crimping Die Assembly
318106–1.
For additional information on COPALUM terminals
and splices, refer to Catalog 82020.
Read these instructions thoroughly before crimping
any terminals or splices.
NOTE
All dimensions on this document are in metric
units [with U.S. customary units in brackets].
i
Figures and illustrations are not drawn to scale
and are for reference only.
Do not use stranded aluminum wire.
i
3. DIE INSTALLATION AND REMOVAL
NOTE
Crimping dies are coated with a preservative to
prevent rust and corrosion. Wipe this preservative
i
from the dies, particularly from the crimping
surfaces.
3.1. Installation
The radii of both dies must match the radii of the tool.
See Figure 1.
Proceed as follows:
2. DESCRIPTION
The die assembly consists of a stationary die
(indenter) and a moving die (anvil).
The crimping die assembly is designed for use in
Hydraulic Tool 69099 to crimp insulation piercing
COPALUM terminals and splices on size 4/0 film–
insulated solid aluminum or copper wire or stranded
copper wire.
For further information concerning setup procedures,
refer to instruction sheet 408–2458, which is
packaged with the hydraulic tool.
E
2007 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
1. Loosen retaining screw in top section of
crimping head. See Figure 1.
2. Insert shank of stationary die into top section of
crimping head and tighten retaining screw.
NOTE
Ensure that the dies are inserted fully and that
the flats" on shanks are facing the operator.
i
3. Activate power unit to advance ram until
setscrew is visible.
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
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LOC B
408-4199
Crimping Die Assembly 318106-1
DANGER
AVOID PERSONAL INJURY. Exercise extreme
5.2. Terminal Crimping Procedure
caution when using power unit. Avoid depressing
foot switch or trigger control when installing die
DANGER
AVOID PERSONAL INJURY. When operating
power unit, exercise caution while holding
assembly.
terminals or wire near crimping area. Never place
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.
3.2. Die Removal
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 removing die
assembly.
4. WIRE SELECTION AND LOADING
Solid aluminum or copper (or a combination of both)
and stranded copper conductors may be crimped in
the same wire barrel under the conditions referenced
in Application Specification 114–2121.
5. WIRE STRIPPING AND CRIMPING PROCEDURES
5.1. Wire Stripping Procedure
NOTE
3. Activate power unit so that moving die advances
and holds terminal in place. Do not deform terminal
wire barrel.
4. Insert stripped wire all the way into terminal wire
barrel. End of wire must be flush with or extend
beyond end of wire barrel as shown in Figure 3,
Detail A.
5. Activate power unit to complete crimp.
6. Refer to Figure 4 and Section 6, CRIMP
INSPECTION.
5.3. Butt Splice Crimping Procedure
1. Position butt splice in stationary die so that end
of splice butts against locator as shown in Figure 3,
Detail B. View port in splice faces stationary die.
2. Activate power unit so that moving die advances
and holds splice in place. Do not deform splice wire
barrel.
1. Select the proper size terminal or splice for the
wire size being used. See Figure 2.
CRIMPING
HEAD
DIE SET
69099
318106-1
WIRE
SIZE
CMA
RANGE
190,000
4/0
to
231,000
WIRE STRIP
LENGTHD
Min.
Max.
19.05
20.65
[0.750]
[0.813]
3. Insert stripped wire all the way into splice wire
barrel.
4. Activate power unit to complete crimp.
5. To crimp other half of butt splice, remove it and
reposition uncrimped half in stationary die and
follow same procedure used to crimp first half of
splice. If splice cannot be turned, turn tool around.
NOTE
Stranded copper wire only.
Butt splices may be slightly bent when crimped
as instructed in Step 5. If this bending is
Figure 2
2. Determine correct terminal or splice wire loading
and CMA range listed in Figure 2.
3. Strip stranded copper wire to dimension
indicated in Figure 2.
NOTE
1. Ensure that the wire size stamped on the
terminal corresponds with the wire size stamped
on the dies.
Do not use stranded aluminum wire.
i
D
COPALUM terminals and splices.
2. Position terminal wire barrel between locators of
stationary die as shown in Figure 3, Detail A. Back
of terminal tongue must face moving die.
1. Loosen retaining screw in top section of
crimping head and remove die.
DANGER
anything within the crimping dies except
It is not necessary to strip film-insulated
i
objectionable, use the crimp procedure in Step 6.
6. To crimp other half of butt splice, remove and
rotate splice 180_ end over end. Reposition
uncrimped half in stationary die as described in
Step 1. If splice cannot be rotated, rotate tool.
Insert wire and then crimp the splice.
aluminum or copper wires.
i
2 of 7
7. Refer to Figure 4 and Section 6, CRIMP
INSPECTION.
Tyco Electronics Corporation
Rev
A
408-4199
Crimping Die Assembly 318106-1
Detail A
Terminal
Detail B
Butt Splice
View Port Faces
Stationary Die
Stationary Die
Locator
Locator
Back of Terminal
Tongue Faces
Moving Die
Position Wire
Barrel Between
Locators
Detail C
Parallel Splice
End of Splice
Butts Against
Locator
Position Splice
Between
Locators
Figure 3
5.4. Parallel Crimping Procedure
1. Position parallel splice between locators as
shown in Figure 3, Detail C.
2. Activate power unit so that moving die advances
and holds splice in place. Do not deform the splice.
3. Insert stripped wires all the way into splice.
Ends of wires must be flush with or extend beyond
ends of splice.
4. Activate power unit to complete the crimp.
NOTE
If COPALUM terminal or splice sticks in die after
crimping, apply a rocking action to remove from
i
die.
7. MAINTENANCE AND INSPECTION
Tyco Electronics recommends that a maintenance
and inspection program be performed periodically to
ensure dependable and uniform terminations. The
crimping die assembly should be inspected once a
month. Frequency of inspection should be adjusted to
suit your requirements through experience.
Frequency of inspection depends on:
1. The care, amount of use, and handling of the
crimping die assembly.
2. The type and size of the product crimped.
5. Refer to Figure 4 and Section 6, CRIMP
INSPECTION.
3. The degree of operator skill.
4. The presence of abnormal amounts of dust and
dirt.
6. CRIMP INSPECTION
5. Your own established standards.
Inspect crimped terminals and splices by checking the
features described in Figure 4. Use only the terminals
and splices that meet the conditions shown in the
“ACCEPT” column. “REJECT” terminals and splices
can be avoided through careful use of instruction in
Rev A
Section 5, and by performing regular die maintenance
as described in Section 7.
Each die assembly is thoroughly inspected before
packaging. Since there is the possibility of damage
during shipment, new die assemblies should be
inspected immediately upon arrival at your facility.
Tyco Electronics Corporation
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408-4199
Crimping Die Assembly 318106-1
ACCEPT
3
1
REJECT
4
TERMINAL
2
WIRE RANGE
6
3
STAMPED HERE
1
2
1
WIRE RANGE
STAMPED HERE
5
1
1
PARALLEL
SPLICE
3
4
4
1
3
1
1
BUTT SPLICE
3
WIRE RANGE
2
STAMPED HERE
2
1
WIRE RANGE
STAMPED HERE
1
Crimps centered. Crimp may be slightly off center but
2
3
CMA of wire being used matches wire range stamped
3
Wire not inserted far enough in terminal or splice. End
of wire must be visible through inspection hole of butt
on terminal or splice and dies.
splices, and be flush with or extend slightly beyond
Wire is visible through inspection hole of butt splice,
end of terminal wire barrel or parallel splice.
and is flush with or extends slightly beyond end of
4
terminal wire barrel.
Excessive flash" indicates wrong wire, terminal,
splice, or die combination was used.
5
On parallel splices, bare wire ends must be flush with
4
CMA of wire being used does not match wire range
stamped on terminal, splice, or dies.
not off end of wire barrel.
2
Crimped off end of splice or terminal.
Insulation entered barrel of terminal or splice. (Stranded
Copper Wire Only.) Check for correct strip length.
or extend slightly beyond end of barrel.
6
Nicked or missing strands.
Figure 4
7.1. Daily Maintenance
7.2. Periodic Inspection
Tyco Electronics recommends that each operator be
responsible for the following steps of daily
maintenance:
1. Remove dust, moisture, and other contaminants
with a clean, soft brush, or a 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.
NOTE
Wipe excess oil from tool, particularly from
crimping area. Oil transferred from the crimping
i
area onto certain terminations may affect the
electrical characteristics of an application.
3. When the dies are not in use, mate them and
store in a clean, dry area.
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Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the die assembly or be supplied to
supervisory personnel responsible for the die
assembly. Though recommendations call for at least
one inspection a month, the frequency should be
based on amount of use, working conditions, operator
training and skill, and your established company
policies. These inspections should include a visual
inspection (Paragraph 7.3) and a crimping chamber
inspection (Paragraph 7.4).
7.3. 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.
2. Inspect crimp area for flattened, chipped, or
broken areas. See Figure 5. Replace worn or
damaged parts.
Tyco Electronics Corporation
Rev
A
408-4199
Crimping Die Assembly 318106-1
Tyco Electronics does not manufacture or market
these gages. The following procedure is
recommended for inspecting the die closures.
Chipped
1. Clean oil or dirt from the die closure areas, and
plug gage elements.
2. Select the proper GO gage. Position gage
element in inner crimp closure of stationary die so
that locator is in notch of gage element. See
Figure 8, Detail A.
3. Assemble and adjust dies to meet the “gage
dimension” indicated in Figure 8, Detail A.
Broken
4. To meet the GO gage conditions, the plug gage
must be able to rotate freely in either direction as
shown in Figure 8, Detail A.
Pitted
Corner
5. Select the proper NO–GO gage. Position gage
element in inner crimp closure of stationary die so
that locator is in notch of gage element. See Figure
8, Detail B.
Figure 5
6. Mate the stationary and moving dies so that
inner crimp surfaces are seated on the NO–GO
gage element.
7.4. Gaging the Crimping Chamber
7. To meet the NO–GO gage conditions, NO–GO
gage element will be held stationary (will not rotate)
by the dies. See Figure 8, Detail B.
This inspection requires the use of a plug gage
conforming to the diameters provided in Figure 6 or 7.
Suggested Plug Gage Design - Inner Crimp
50.8
[2.00]
C"
F"
Min.
1/2 C"
D"
GO Dim.
G"
E" Dia.
Inner Crimp Die
Closure
Configuration
DIE SET
NUMBER
318106-1
NO-GO Dim.
GAGE ELEMENT DIMENSIONS
(A" Dia.)
GO
NO-GO
C"
D"
E" Dia.
F"
G"
7.874 - 7.882
8.125 - 8.128
4.57
13.46
4.57
12.19
1.47
[.3100 - .3103]
[.3199 - .3200]
[.180]
[.530]
[.180]
[.480]
[.058]
Figure 6
Rev
A
Tyco Electronics Corporation
5 of 7
408-4199
Crimping Die Assembly 318106-1
Suggested Plug Gage Design - Outer Crimp
M"
50.8
J"
K"
[2.00]
1/2 J"
Min.
N"
L" Dia.
GO Dim.
NO-GO Dim.
Outer Crimp Die
Closure
Configuration
DIE SET
NUMBER
318106-1
GAGE ELEMENT DIMENSIONS
(A" Dia.)
GO
NO-GO
J"
11.430 - 11.438
11.783 - 11.786
6.35
[.4500 - .4503]
[.4639 - .4640]
[.250]
K"
L" Dia.
M"
N"
5.08
6.35
12.19
2.46
[.200]
[.250]
[.480]
[.097]
Figure 7
8. Inspect the right and left outer crimp closures in
the same manner as Steps 2 through 7. See
Figure 8, Details C and D.
If both the inner crimp and the outer crimp closures
meet the plug gage conditions, the die closures may
be considered dimensionally correct and lubricated
with a thin coat of any good SAE 20 motor oil. If the
dies do not conform, the dies must be replaced or
repaired before returning them to service. See
Section 8, REPLACEMENT AND REPAIR.
For additional information concerning the use of the
plug gage, refer to Instruction Sheet 408–7424.
6 of 7
8. REPLACEMENT AND REPAIR (Figure 9)
Order replacements through your representative, or
call 1–800–526–5142, or send a facsimile of your
purchase order to 717–986–7605, or write to:
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
9. REVISION SUMMARY
S Updated document to corporate requirements
S Changed dimension lines in Figures 6 and 7
Tyco Electronics Corporation
Rev
A
408-4199
Crimping Die Assembly 318106-1
Inspection of Inner Crimp Closure
Detail A GO Gage
Inspection of Outer Crimp Closure
Detail C GO Gage
GO Gage
Rotates
Freely in
Either
Direction
Left Die
Right Die
Closure
Closure
GO Gage
Rotates
Freely in
Either
Direction
42.27
[1.664]
Stationary Die
Locators
Locator in
Notch of
Gage Element
Detail B NO-GO Gage
Detail D NO-GO Gage
Right Die
Left Die
Closure
Closure
NO-GO Gage
Will Not
Rotate
NO-GO Gage
Will Not
Rotate
42.27
[1.664]
Die Crimp
Surfaces Seated
Locator in Notch of
Locator in Notch of
on Gage Element
Gage Element
Gage Element
Figure 8
3
ITEM
4
2
5
PART
NUMBER
DESCRIPTION
QTY PER
ASSY.
1
314993-1
2
314992-1
3
308131-1
LOCATOR
2
4
308133-1
PLATE
2
5
1-59573-7
RIVET
2
MOVING DIE, (Anvil)
STATIONARY DIE
(Indenter)
1
1
1
Figure 9
Rev
A
Tyco Electronics Corporation
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