Instruction Sheet
408-2433
Insulation Piercing
COPALUM* Terminal and
(was IS 2433)
Splice Crimping Heads
1. INTRODUCTION
Do not use stranded aluminum wire.
Rev A
Assembly
Toggle Lever Shank
This instruction sheet provides instructions on product
application and Maintenance and Inspection for
Insulation Piercing COPALUM Terminal and Splice
Crimping Heads (68081 and 68082) used in
Pneumatic Tool 69015. These crimping heads are
used to crimp COPALUM Terminals and Splices on
No. 8 thru 6 film insulated solid aluminum or copper
wire or stranded copper wire.
NOTE
21 JAN 09
Thumb Control
Pins
Mounting Lugs
Link(s)
Wire Size Plus
Crimp Symbol
Appear on
Surface of Anvil
i
Toggle Arm
Basic instructions on the use of these heads, wire
preparation, etc. are provided in Section 2,
INSTRUCTIONS. Section 3 features terminal or
splice Crimp Inspection Procedure. Section 4
contains a Maintenance and Inspection Procedure
which will enable you to establish a tool certification
program.
Crimping heads are coated with preservative to
prevent runt and corrosion. Wipe this preservative
from heads, particularly from the crimping areas. For
further instructions relative to the 69015 tool, refer to
the instructions packaged with the tool.
NOTE
All dimensions in this document are in millimeters
[with inches in brackets]. Figures and Illustrations
i
Release Lever
Figure 1
2. Remove assembly pins from mounting lugs as
shown in Figure 1.
3. Pull toggle arm forward and insert toggle lever
shank of crimping head all the way into hole in
toggle arm until toggle lever snaps in place. See
Figure 1.
4. Align holes in crimping head links with holes in
mounting lugs.
are for reference only and are not drawn to scale.
5. Insert assembly pins.
Reasons for reissue are provided in Section 5,
REVISION SUMMARY.
6. Connect air supply to tool 586 to 689 kPa
[85 to 11 psi].
7. Tool is now ready for operation.
2. INSTRUCTIONS
DANGER
2.2. Crimping Head Removal
Avoid personal injury. Always keep fingers clear
of crimping jaws when actuating air tool. Do NOT
operate tool without having head installed and
latched in place.
Disconnect tool from air supply.
!
1. Remove assembly pins.
2.1. Crimping Head Installation
CAUTION
CAUTION
Disconnect tool from air supply.
!
2. Lower head away from mounting lugs, twist
head 90° and remove from toggle arm.
3. Reinstall assembly pins.
1. Select the correct crimping head for the wire
size being used. Wire size and the insulation
piercing crimp symbol ( ) appear on one jaw as
shown in Figure 1.
Y
E
2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
2.3. Wire Selection/Loading
Solid aluminum or copper (or a combination of both)
and stranded copper conductors may be crimped in
the same wire barrel under the following conditions:
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
1 of 8
LOC B
408-2433
Insulation Piercing COPALUM Terminal and Splice Crimping Heads
NOTE
Conductors must always be within CMA limits of
wire barrel.
See Figure 2, Detail D
Four identical rectangular conductors, where one
conductor thickness is equal to or greater than 1/4 the
width of one conductor, may be crimped without
removing film insulation.
i
A. Condition 1
See Figure 2, Detail A
Maximum CMA fill for copper conductor should not
exceed 40% of total CMA. For example, six No. 14
solid aluminum 12.14 mm2 [24,000] Cir Mil plus one
No. 8 stranded copper 8.10 mm2 [16,000] Cir Mil
equals 40,000 Cir Mil. The one No. 8 stranded copper
conductor is approximately 40% of total CMA
20.24 mm2 [40,000] Cir Mil being crimped.
A
Round Copper
or Aluminum
(10 Equal Size)
Square Copper
or Aluminum
(6 Equal Size)
B
C
Wire Barrel
One No. 8 Str. Copper:
Six No. 14 Sol.
8.10 mm2 [16,000] Cir
Aluminum: 12.14
2
Mil
(Not to Exceed 40%
mm [24,000] Cir Mil D
of Total CMA)
E
T
W
T
D. Condition 4
W
T 1/4 W
T 1/4 W
10.52 mm2 [20,800] Cir Mil
6.07 mm2 [12,000]
Cir Mils = 59% LoadĆ
ing of 10.52 mm2
[20,800] Cir Mils
Terminal and
Splice Sizes
E. Condition 5
See Figure 2, Detail E
Two identical rectangular conductors, where
thickness of one conductor is equal to or less than 1/4
of the width of one conductor, may be crimped
without removing film insulation.
F. Condition 6
See Figure 2, Detail F
In some instances, it may not be possible to fit a
particular CMA loading into the normally
recommended terminal or splice. In these cases,
where seven or more equal round, or a combination
of solid aluminum and stranded copper conductors
are used, and the total CMA is at least 50% of
maximum CMA of the next larger size terminal or
splice, the larger size may be used. Example: three
No. 14 solid conductors equal about 6.07 mm2
[12,000] Cir Mils. This falls within the CMA range of a
12–10 terminal or splice accepting a maximum CMA
of 6.63 mm2 [13,100] circular mils. However, it may
not be possible to insert all three conductors into the
recommended terminal or splice. It is possible to
insert all three conductors into a No. 8 size terminal or
splice accepting a CMA range of 6.63–10.52 mm2
[13,100–20,800] circular mils. The 6.07 mm2 [12,000]
circular mils amounts to 59% loading of the maximum
CMA for No. 8 size terminal or splices. Therefore, No.
8 size terminals or splices may be used.
G. Condition 7
When using a variety of solid conductor sizes, none of
the conductors should vary more than one (1) wire
gage. (Ideally not more than 1/2 wire gage.)
2.4. Wire Preparation
Area - Circular Mils
NOTE
Figure 2
Do not use stranded aluminum wire.
i
B. Condition 2
See Figure 2, Detail B
A maximum of ten equal size round conductors may
be crimped without removing film insulation.
C. Condition 3
See Figure 2, Detail C
A maximum of six equal size square conductors may
be crimped without removing film insulation.
2 of 8
1. Select the proper terminal or splice wire size
and crimping head combination for the wire size
being used. See Figure 3.
2. Determine correct terminal or splice wire loading
by referring to Paragraph 2.3, and CMA range
listed in Figure 3.
3. Strip stranded copper wire to dimension
indicated in Figure 3.
Tyco Electronics Corporation
Rev A
408-2433
Insulation Piercing COPALUM Terminal and Splice Crimping Heads
NOTE
It is not necessary to strip film insulated
A (Terminals)
aluminum or copper wires.
Wire
i
Barrel
Between
Locators
Terminal
Back of
Terminal
Faces Upper
Butt Splice
Crimping Jaw
Parallel Splices
End of Wire is
HEAD
WIRE
SIZE
68081
8
WIRE STRIP LENGTH
CMA RANGE
MIN.
MAX.
10.31
11.91
[.406]
[.469]
Flush with or
B (Butt Splices)
Slightly Beyond
2
68082
6.63-10.52 mm
[13,100-20,800]
10.52-16.75 mm
6
2
Wire Barrel
[20,800-33,100]
Splice
Butts
Window in Splice
Faces Upper Jaw
Against
Figure 3
Locator
2.5. Crimping Procedure
DANGER
Extended
Avoid personal injury. When operating air tool,
exercise caution when holding terminals, splices,
or wire near crimping area.
End of Wire Butts
A. Terminals
Against Splice Wire Stop
Ensure that the wire size stamped on the terminal
corresponds with the wire size stamped on the
crimping head link.
C (Parallel Splices)
Position
Splice
1. Position terminal wire barrel between locators of
lower jaw as shown in Figure 4A. Back of terminal
tongue must face upper jaw.
Between
Locators
2. Insert wire into terminal wire barrel until end of
wire is flush with or extended slightly beyond end
of wire barrel. Hold terminal in place, press thumb
control and hold it down until crimping stroke is
completed.
3. Release thumb control and remove crimped
terminal.
End of Wires are Flush
with or Extended Slightly
Beyond Wire Barrel
4. Refer to Section 3 and Figure 5 for crimp
inspection.
Figure 4
B. Butt Splices
2. Insert wire into place until it butts against splice
wire stop. Hold splice in place, press thumb control
and hold it down until crimping stroke is completed.
Ensure that wire size stamped on the splice
corresponds with the wire size stamped on the
crimping head link.
3. Release thumb control and remove crimped
splice.
1. Position butt splice in lower jaw so that end of
splice butts against locator and window in splice
faces upper jaw. See Figure 4B.
Rev
A
4. To crimp other half of butt splice, remove it and
reposition uncrimped half in crimping jaws and
follow same procedure used to crimp first half of
splice. If splice cannot be turned, turn tool around.
Tyco Electronics Corporation
3 of 8
408-2433
Insulation Piercing COPALUM Terminal and Splice Crimping Heads
NOTE
C. Parallel Splices
Butt splices may be slightly bent when crimped
as instructed in step (4). If this bending is
i
Ensure that wire size stamped on the splice
corresponds with the wire size stamped on the
crimping head link.
objectionable, use the following crimping
procedure:
5. To crimp other half of butt splice, remove and
rotate splice 180° end over end. Reposition
uncrimped half in lower jaw as described in step
(1). If splice cannot be rotated, rotate tool. Insert
wire and then crimp the splice.
1. Position splice between locators as shown in
Figure 4C.
2. Insert wires into splice until ends of wires are
flush with or extended slightly beyond wire barrel.
Hold splice in place, press thumb control and hold
it down until crimping stroke is completed.
6. Refer to Section 3 and Figure 5 for crimp
inspection.
ACCEPT
REJECT
Wire Range
Stamped
on Bottom
of Tongue
Terminal
Wire Range
Stamped on Bottom
of Tongue
Parallel Splice
Butt Splice
Wire Range
Stamped Here
Wire Range
Stamped Here
Figure 5
4 of 8
Tyco Electronics Corporation
Rev A
408-2433
Insulation Piercing COPALUM Terminal and Splice Crimping Heads
3. Release thumb control and remove crimped
splice.
cloth. Re–lubricate head as instructed in Paragraph
4.3 before placing it back in service.
4. Refer to Section 3 and Figure 5 for crimp
inspection.
4.2. Visual Inspection
NOTE
If COPALUM Terminal or Splice sticks in die after
crimping, apply a rocking action to remove from
i
die.
3. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 5.
Use only terminals and splices meeting the conditions
shown in the “ACCEPT” column. “REJECT” terminals
and splices can be avoided through careful use of
instructions in Section 2, and by performing regular
crimping head maintenance as provided in Section 4.
4. MAINTENANCE/INSPECTION PROCEDURE
Tyco Electronics recommends that a
maintenance/inspection program be performed
periodically to ensure dependable and uniform
terminations. Crimping heads should be inspected at
least once a month. Frequency of inspection may be
adjusted to suit your requirements through
experience. Frequency of inspection is dependent
upon:
1. Visually inspect the crimping head for missing
pins or retaining rings. If parts are missing or
defective, refer to Figure 10 for customer
replaceable parts.
2. Inspect the die closure surfaces of the head for
broken, pitted, or chipped conditions. Although dies
may gage within permissible limits, worn or
damaged die closure surfaces are objectionable
and can affect the quality of the crimp. Examples
of possible damaged die closure surfaces are
shown in Figure 6.
4.3. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with a good grade S.A.E. No. 20 motor oil as follows:
Heads used in daily production – Lubricate daily
Heads used daily (occasional) – Lubricate weekly
Heads used weekly – Lubricate monthly
Wipe excess oil from head, particularly from crimping
area. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
S The care, amount of use, and handling of the
head.
S The type and size of the products crimped.
S The degree of operator skill.
S The presence of abnormal amounts of dust and
dirt.
S Your own established standards.
All crimping heads are thoroughly inspected before
packaging. Since there is a possibility of damage in
shipment, new heads should be inspected in
accordance with the following instructions when
received in your plant.
Broken
Pitted
4.1. Cleaning
CAUTION
Do not allow deposits of dirt, grease and foreign
matter to accumulate on the die closure surfaces.
!
These deposits may cause excessive wear,
thereby affecting the quality of the crimp.
The crimping head should be immersed in a reliable
commercial de–greasing compound to remove
accumulated dirt, grease and foreign matter. Remove
remaining de–greasing compound with a lint–free
cloth. When de–greasing compounds are not
available, head may be wiped clean with a lint–free
Rev A
Tyco Electronics Corporation
Chipped
Figure 6
5 of 8
408-2433
Insulation Piercing COPALUM Terminal and Splice Crimping Heads
4.4. Die Closure Inspection
Every crimping head is inspected for proper die
closure before packaging. An inspection should be
performed periodically to check the die closure for
excessive wear. The die closure inspection is
accomplished using the GO NO–GO plug gages.
Tyco Electronics neither manufactures nor sells plug
gages. A suggested plug gage design and the GO
NO–GO dimensions of the plug gage members are
listed in Figures 7 and 8. the following procedure is
recommended for inspecting the die closures.
1. Clean oil or dirt from die closure areas, and plug
gage members.
2. Select the proper GO gage. Position gage
member in lower jaw inner crimp closure so that
locator is in notch of gage member. See Figure 9,
Detail A.
3. Close the crimping jaws until they are bottomed
but not under pressure.
4. To meet the GO gage conditions, the plug gage
must be free to rotate in either direction as shown
in Figure 9, Detail A.
5. Select the proper NO–GO gage. Position gage
member in lower jaw inner crimp closure so that
locator is in notch of gage member. See Figure 9,
Detail B.
6. Close the crimping jaws so that inner crimp
surfaces are seated on the NO–GO member.
SUGGESTED PLUG GAGE DESIGN - INNER CRIMP
Inner Crimp Die
50.8 [2.00] Min.
A" Dim.
GO}
68081
68082
D"
NO-GO
GAGE MEMBER{ DIM'S. B"
DIA.
GO
1/2 C"
E" Dia.
B" NO-GO Dim.
B" GO Dim.
DIE CLOS. DIM'S. A"
HEAD
C"
F"
Closure Configuration
G"
C"
D"
E" DIA.
F"
G"
1.65 [.065]
7.37 [.290]
1.65 [.065]
7.87 [.310]
0.61 [.024]
1.90 [.075]
7.62 [.300]
1.90 [.075]
8.89 [.350]
0.61 [.024]
NO-GO
2.30
3.25
2.997-3.005
3.249-3.251
[.1180]
[.1280]
[.1180-.1183]
[.1279-.1280]
3.28
3.53
3.277-3.284
3.528-3.531
[.1290]
[.1390]
[.1290-.1293]
[.1389-.1390]
Figure 7
SUGGESTED PLUG GAGE DESIGN - OUTER CRIMP
Outer Crimp Die
50.8 [2.00] Min.
H" Dim.
HEAD
68081
68082
K"
P" NO-GO Dim.
P" GO Dim.
DIE CLOS. DIM'S. H"
GO}
NO-GO
GAGE MEMBER{ DIM'S. P"
DIA.
GO
1/2 J"
L" Dia.
N"
J"
K"
L" DIA.
M"
N"
2.29 [.090]
3.30 [.130]
2.29 [.090]
7.87 [.310]
1.14 [.045]
2.54 [.100]
3.30 [.130]
2.54 [.100]
8.89 [.350]
1.50 [.059]
NO-GO
4.445
4.801
4.445-4.453
4.798-4.801
[.1750]
[.1890]
[.1750-.1753]
[.1889-.1890]
4.953
5.309
4.953-4.961
5.306-5.309
[.1950]
[.2090]
[.1950-.1953]
[.2089-.2090]
{Material - Tool Steel;
J"
M"
Closure Configuration
}GO" die closure dimensions apply when jaws are bottomed, but not under pressure
Figure 8
6 of 8
Tyco Electronics Corporation
Rev
A
408-2433
Insulation Piercing COPALUM Terminal and Splice Crimping Heads
INSPECTION OF INNER CRIMP CLOSURE
INSPECTION OF OUTER CRIMP CLOSURE
DETAIL A
GO GAGE
DETAIL C
GO GAGE
Right Die
Closure
Left Die
Closure
Jaws Bottomed
But Not Under
Pressure
Go Gage
Rotates
Freely in
Either
Direction
Go Gage
Rotates
Freely in
Either
Direction
Locator
Locator
Locator in Notch
of Gage Member
Lower Jaw
DETAIL B
NO-GO
GAGE
DETAIL D
NO-GO
GAGE
Left Die
Closure
Right Die
Closure
Jaws will Not Bottom
NO-GO Gage
will Not Rotate
Crimp Surfaces
Seated on
Gage Member
Locator in Notch of Gage Member
NO-GO Gage
will Not Rotate
Locator in Notch of Gage Member
Figure 9
Rev A
Tyco Electronics Corporation
7 of 8
408-2433
Insulation Piercing COPALUM Terminal and Splice Crimping Heads
4.5. Replacement Parts
7. To meet the NO–GO gage conditions, jaw
bottoming surfaces will NOT bottom, and NO–GO
gage member will be held stationary (will not
rotate) by the dies. See Figure 9, Detail B.
It may be advantageous to stock certain replaceable
parts to prevent loss of production time. Figure 10
lists the customer replaceable parts that can be
purchased from Tyco Electronics. Order
replacements through your Tyco Electronics
Representative, or call 1–800–526–5142, or send a
facsimile of your purchase order to 717–986–7605, or
write to:
8. Inspect the right and left outer crimp closures in
the same manner as steps (2) thru (7). See Figure
9, Details C and D.
9. If both the inner crimp and the outer crimp
closures meet the GO NO–GO gage conditions,
the die closures may be considered dimensionally
correct. If you find that the die closures do not
conform with the GO NO–GO gage conditions,
contact your local Tyco Electronics Representative.
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
5. REVISION SUMMARY
S Updated document to corporate requirements
S New format
See Footnote for Locator Parts Replacement
ITEM
DESCRIPTION
QTY
TOOL NUMBERS
68081
68082
1
LINK
1
1-59649-9
2-59649-0
2
LOWER JAW, with Locators
1
307829-1
307829-2
3
UPPER JAW
1
307792-1
307792-2
4
RING, Retaining
4
1-21048-6
1-21048-6
5
PIN, Retaining
2
300042
300042
6
PIN, Pivot
1
300115
300115
7
LINK
1
300114
300114
8
RING, Retaining
6
300102
300102
9
PIN, Retaining
3
302563
302563
10
LINK, Toggle
2
302562
302562
11
LEVER, Toggle
1
302561
302561
RIVET
2
1-59573-5
1-59573-5
PLATE, Locator
2
308134-1
308134-1
LOCATOR
2
308132-1
308132-1
D
DIf locators are worn and need replacement, order parts from this area of table.
Figure 10
8 of 8
Tyco Electronics Corporation
Rev
A
