408-4199 Datasheet, PDF (2/7 Pages) Tyco Electronics – This instruction sheet covers the application and maintenance procedures for Crimping Die Assembly

Crimping Die Assembly 318106-1
408-4199
DANGER
AVOID PERSONAL INJURY. Exercise extreme
caution when using power unit. Avoid depressing
foot switch or trigger control when installing die
assembly.
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
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.
DANGER
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
Do not use stranded aluminum wire.
i
1. Select the proper size terminal or splice for the
wire size being used. See Figure 2.
CRIMPING
HEAD
DIE SET
WIRE
SIZE
CMA
RANGE
190,000
69099
318106-1
4/0
to
231,000
DStranded copper wire only.
Figure 2
WIRE STRIP
LENGTHD
Min. Max.
19.05
[0.750]
20.65
[0.813]
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
i
It is not necessary to strip film-insulated
aluminum or copper wires.
5.2. Terminal Crimping Procedure
DANGER
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.
1. Ensure that the wire size stamped on the
terminal corresponds with the wire size stamped
on the dies.
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.
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.
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
i
Butt splices may be slightly bent when crimped
as instructed in Step 5. If this bending is
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.
7. Refer to Figure 4 and Section 6, CRIMP
INSPECTION.
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