408-2281 Datasheet, PDF (2/12 Pages) TE Connectivity Ltd – Crimping Die Assemblies

408-2281
1. INTRODUCTION
The crimping die assemblies are designed to be installed into the hydraulic crimping heads listed in Table 1
and are used to crimp COPALUM sealed terminals and splices. Read these instructions thoroughly before
crimping any terminals or splices.
Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY.
NOTE
Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Illustrations are for reference only and are not
drawn to scale.
2. DESCRIPTION
Each crimping die assembly consists of a stationary die (nest) and moving die (anvil). Each die features an
alignment dot on the front of the die. See Figure 1.
3. DIE ASSEMBLY INSTALLATION
For information concerning die installation and general performance of the hydraulic crimping head, refer to the
instruction sheet packaged with the crimping head.
DANGER
To avoid personal injury, ALWAYS DISCONNECT electrical and air supply to power unit before installing the hydraulic
crimping head or die assembly.
In order to achieve proper mating of the dies during installation, ensure that:
— the shanks of the dies are offset to the same surface of the die, but that the alignment dots align and
face the operator
— the anvil moves and the nest is stationary
CAUTION
DO NOT mix dies from different or the same die assemblies (because of inconsistent wearing) — it is important that the dies
are used as the set.
DANGER
To avoid personal injury, make sure to close the yoke of the hydraulic crimping 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 die assembly.
4. CRIMPING PROCEDURE
Select the die assembly and terminal or splice, and prepare the wire as follows:
1. Refer to Figure 2/Table 2 to select the appropriate die assembly and terminal or splice according to
the wire.
NOTE
For aluminum-to-aluminum application, butt splices will accept the same wire size at either end. For aluminum-to-copper
application, the copper wire size must be smaller to compensate for differences in the electrical properties of copper and
aluminum. This also applies when using copper wire in a terminal as listed in Table 2.
2. Cut the end of the wire perpendicular to the wire; DO NOT distort the shape of the wire. It is
recommended to chamfer the edge around the group of wires. See Figure 2. The chamfer will aid in
the insertion of the wire into the terminal or splice.
3. Strip the wire to the length indicated in Figure 2/Table 2. DO NOT nick or cut the wire strands. The
strip length for the wire will depend on the number of insulation layers covering the wire.
There are two approved methods for crimping the terminals and splices using these die assemblies and
hydraulic crimping heads. Proceed as follows:
Rev CK
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