1-307586-3 [MACOM]
Crimping Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts;
| 型号： | 1-307586-3 |
| 厂家： | 
Tyco Electronics |
| 描述： | Crimping Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts |
| 文件： | 总12页 (文件大小：317K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Instruction Sheet
Crimping Die Assemblies for
COPALUM* Terminals and Splices
and HF-30 Pin and Socket Contacts
408-2353
25 MAR 10 Rev B
Crimping Head (Ref)
Tool Head
Radii
Retaining Screw
Stationary Die (Nest)
Die Radii
Setscrew
in Ram
CRIMPING DIES USED IN . . .
CRIMPING HEAD
69082, 1752786-1
CRIMPING HEAD
69099, 1752868-1
68043 68044 68045
68046 68047
68034 68035 68036
68037 68037--1 68050
Moving Die
(Indenter)
Flats on Shank
68048 68049
Figure 1
aluminum or copper{ wire and HF--30 Pin and Socket
Contacts for stranded aluminum and copper wire
sizes specified in Figure 2B.
1. INTRODUCTION
This instruction sheet covers the use of Crimping Die
Assemblies listed in Figure 1, which are used to crimp
COPALUM Terminals and Splices and HF--30 Pin and
Socket Contacts. The die assemblies are used in
Crimping Heads 69082, 69099, 1752786--1, and
1752868--1. Refer to instruction sheet packaged with
the crimping head for information concerning die
installation and general performance of the head.
Read these instructions thoroughly before using the
die assemblies.
Dies are coated with preservative to prevent rust and
corrosion. Wipe this preservative away from dies,
particularly from crimping areas.
For further instructions on the hydraulic power unit
and hydraulic crimping heads, refer to the instructions
packaged with these tools.
2.1. Die Installation
See Section 7, REVISION SUMMARY, for revision
information.
AVOID PERSONAL INJURY. Exercise extreme
caution when using power unit. Avoid depressing
foot switch or trigger control when installing or
removing die assemblies. DO NOT MIX DIE
COMPONENTS FROM DIFFERENT DIE SETS.
DANGER
All dimensions on this document are in metric
units [with U.S. customary units in brackets].
Figures and illustrations are for reference only
and are not drawn to scale.
NOTE
i
The radii of both dies must match the radii of the tool.
See Figure 1.
2. DESCRIPTION
Crimping head No. 69099 is illustrated throughout this
publication; however, die insertion, die removal and
crimping instructions are the same for 69099, 69082,
1752786--1, and 1752868--1 crimping heads.
The die assemblies consist of stationary dies (nest)
and moving dies (indenter). Refer to Figure 2A
(COPALUM contacts) or Figure 2B (HF--30 Contacts)
to ensure the compatibility of die assemblies,
crimping heads, and terminals and splices. These
dies are used to crimp COPALUM Terminals and
Splices on No. 8 through 500 MCM stranded or solid,
Proceed as follows:
1. Loosen retaining screw in top section of
crimping head. See Figure 1.
{Butt Splices Only. Refer to Paragraph 3.3
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
E2010 Tyco Electronics Corporation, Berwyn, PA
1 of 12
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
LOC B
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
2. Insert shank of stationary die into top section of
crimping head and tighten retaining screw.
See Figure 2A for COPALUM Terminal and Splices
or Figure 2B for HF--30 Pin and Socket Contacts.
Ensure that the dies are inserted fully and that
the “flats” on shanks are facing the operator.
NOTE
2. Strip wire to dimension indicated in Figure 2A
for COPALUM Terminals and Splices or Figure 2B
for HF--30 Pin and Socket Contacts.
i
3. Activate power unit to advance ram until
setscrew is visible.
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.
CAUTION
DANGER
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.
3.2. Crimping COPALUM Terminals
5. Activate power unit to complete cycle and allow
ram to return to down position.
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 and HF -30 pin
and socket contacts.
2.2. Die Removal
1. Loosen retaining screw in top section of
crimping head and remove die.
1. Ensure that the wire size stamped on the
terminal corresponds with the size marked on the
dies.
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.
DANGER
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.)
3. WIRE STRIPPING AND CRIMPING PROCEDURE
3.1. Wire Stripping Procedure
NOTE
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.
1. Select the proper size terminal, splice, or HF--30
pin and socket contact for the wire size being used.
i
WIRE STRIP LENGTH
WIRE
SIZE
CRIMPING
DIE ASSY
CRIMPING
HEAD
mm2
CMAD RANGE
MIN
MAX
8
6.638 -- 10.540
10.540 -- 16.772
16.772 -- 26.652
26.652 -- 42.412
42.412 -- 60.55
60.55 -- 76.26
13,100 -- 20,800
20,800 -- 33,100
33,100 -- 52,600
52,600 -- 83,700
83,700 -- 119,500
119500 -- 150,500
150,500 -- 190,000
190,000 -- 231,000
231.000 -- 300,000
300,000 -- 380,000
380,000 -- 478,000
478,000 -- 600,000
68043
68044
68045
68046
68047
68048
68049
68050
68034
68035
68036
68037
10.32 [.4062]
14.29 [.5625]
11.90 [.4687]
15.88 [.6250]
6
4
69099
1752868-- 1
2
1/0
18.25 [.7187]
19.84 [.7812]
2/0
3/0
76.26 -- 96.27
4/0
96.27 -- 117.049
117.049 -- 152.01
152.01 -- 192.55
192.55 -- 242.20
242.20 -- 304.02
19.10 [.75]
28.58 [1.125]
31.75 [1.250]
34.93 [1.375]
38.1 [1.50]
20.64 [.8125]
31.75 1.250
34.93 [1.375]
38.1 [1.50]
250 MCM
300 MCM
400 MCM
500 MCM
69082
1752786-- 1
41.28 [1.625]
DCircular Mil Area
Figure 2A
(For Crimping COPALUM Terminals and Splices -- See Paragraphs 3.2, 3.3, and 3.4)
2 of 12
Tyco Electronics Corporation
Rev B
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
HF-30 Socket
Contact Assembly
Nest (Stationary Die)
2
Part Number,
Revision
Information
1
HF-30 Pin Contact Assembly
Ensure Terminal Dash Number Identifier
Indenter (Moving Die)
Stamped on Terminal Agrees with Crimp
Die Assembly Part Number and Wire
Size Prior to Crimping
WIRE STRIP
LENGTH
(mm)
STAMPED
WIRE AREA
(mm2)
NOMINAL
WIRE
CMA
SWIRE
SIZE
SCRIMPING
DIE
STERMINAL
DASH NO.
IDENTIFIER
SCRIMPING DIE
EMBOSSMENT
IDENTIFIER
WIRE
TYPE-
CRIMPING
HEAD
(mm2)
ASSY.
MIN MAX
23.4 26.6
23.4 26.6
25.9 29.1
25.9 29.1
29.7 32.9
29.7 32.9
29.7 32.9
29.7 32.9
185
150
240
185
300
240
400
300
Alum
Copper
Alum
185
150
240
185
300
240
400
300
365,102
296,029
473,646
365,102
592,058
473,646
789,410
592,058
-- 1
-- 1
-- 2
-- 2
-- 3
-- 3
-- 4
-- 4
300
300
400
400
600
600
500
500
-- -- -- z
-- -- -- z
-- -- -- z
Copper
Alum
-- -- -- z
69082
1752786--1
68037--1zz
68037--1zz
68037zz
68037zz
Copper
Alum
Copper
SEnsure terminal dash number, crimp die assembly part number including its associated embossment identifier, and wire size stamped
on wire, all agree prior to crimping. z Contact Tyco Electronics Engineering for preliminary part number information. zzPending
product qualification approval.
Figure 2B
(For Crimping HF--30 Pin and Socket Contacts -- See Paragraph 3.5)
Detail A
COPALUM
Terminal
Stationary Die
Detail B
COPALUM
Butt Splice
Center Wire
Barrel in Die
View Port Faces
Stationary Die
End of Splice
Flush with
Side of Die
Top of Terminal
Tongue Faces
Moving Die
End of Wire
Butts Against
Wire Stop
Moving Die
End of Wire Must be Flush
with or Extend Beyond End
of Wire Barrel
Figure 3 (cont’d)
Rev B
Tyco Electronics Corporation
3 of 12
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
Detail C
COPALUM
Parallel Splice
Center
Splice in
Ends of Wires Must be
Die
Flush with or Extend
Beyond Ends of Splice
Same Criteria Applies
to Pin Contact
Hydraulic Crimp Head
Detail D
HF -30 Contact
Stationary Die (Nest)
Pin Contact
Assembly HF-30
End of Barrel Flush
with Edge of Die
Socket Contact
Wire inserted fully into contact
until insulation bottoms on edge
of contact. No wire strands
should be visible.
Assembly HF-30
Housing Stop on
Bottom
Moving Die
(Indenter)
HF-30 Contact Location
Detail E
Stationary Die (Nest)
Flat Planar Surface
of Crimp Die Nest
Middle Plane of Contact
Contact Location: The middle plane
of contact should be parallel to the
planar surface of the crimp die nest.
This will prevent twist in the crimp
relative to the planar mating surface
of the contact. This applies to both
pin and socket contacts.
Pin Contact
Assembly
HF-30
Figure 3 (end)
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Tyco Electronics Corporation
Rev B
408-2353
3.4. Crimping Procedure (COPALUM Parallel Splices)
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
3. Activate power unit so that moving die advances
and holds terminal in place. Do NOT deform
terminal wire barrel.
1. Center parallel splice in stationary die as shown
in Figure 3, Detail C.
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. See Figure 3, (Detail D and E), for HF--30
Contacts.
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.
5. Activate power unit to complete crimp.
4. Activate power unit to complete the crimp.
6. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
If terminal or splice sticks in die after crimping,
apply rocking action to remove from die.
NOTE
3.3. Crimping Procedure (COPALUM Butt Splice)
i
1. Position butt splice in stationary die so that end
of splice is flush with sides of dies and view port in
splice is facing stationary die. See Figure 3,
Detail B.
5. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
3.5. Crimping Procedure (HF-30 Pin and Socket
Contacts)
2. Activate power unit so that moving die advances
and holds splice in place. Do NOT deform splice
wire barrel.
1. Ensure the terminal dash number, crimp die
assembly, and wire size agree with table in
Figure 2B prior to crimping.
3. Insert stripped wire into splice wire barrel until
end of wire butts against wire stop as shown in
Figure 3, Detail B.
2. Visually inspect contacts for presence of insert.
See Figure 4.
Verify perforated insert is present prior to
crimping contact assembly. Crimp will not
function properly without insert.
DANGER
For aluminum -to -aluminum applications, butt
splices will accept the same wire size at either
end. For aluminum -to -copper applications,
however, the size of the copper wire must be
“stepped down” to the next smaller wire size to
compensate for differences in the physical
properties of copper and aluminum. Determine
correct splice wire loading by referring to CMA
range listed in Figure 2. If “stepping down” to a
smaller wire size is not desirable, i.e., if
NOTE
i
3. Center pin or socket contact wire barrel in
stationary die as shown in Figure 3, Detail D & E.
4. Activate power unit so that moving die advances
and holds contact in place. Do NOT deform the
contact wire barrel.
aluminum -to -copper applications are to be made
using the same size wire at each end of the butt
splice, Tyco Electronics recommends that the
perforated sleeve be removed from inside that
particular end of splice that is to be crimped on
copper wire. When two or more wires are used in
either end of butt splice, combined
5. Insert properly stripped wires all the way into
contact. Insulation should butt up against contact
wire barrel, see criteria identified in Figure 3,
Detail D.
6. Activate power unit to complete the crimp.
cross -sectional area must be within the CMA
range listed for the splice in Figure 2.
If contact sticks in die after crimping, apply
rocking action to remove from die. Use Tyco
Electronics Lubricant (pat number 168433 -1) to
prevent sticking of HF -30 contacts in crimping
dies. Apply a thin coat to die surfaces
periodically. Do NOT lubricate excessively.
Remove excess lubricant from surface as
required. Lubricant transferred from the crimp
area onto certain terminations may affect the
electrical characteristics of an application.
NOTE
i
4. Activate power unit to complete crimp.
5. To crimp other half of butt splice, remove and
rotate splice 180_ end--over--end. If splice cannot
be rotated, rotate crimping head. Reposition
uncrimped half in stationary die as described in
Step 1. Insert wire and then crimp the splice.
6. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
7. Refer to Figure 5B and Section 4, CRIMP
INSPECTION.
Rev B
Tyco Electronics Corporation
5 of 12
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
Crimping Die Assemblies for COPALUM* Terminals and Splices and HF-30 Pin and Socket Contacts
HF -30 Socket Contact Assembly
HF -30 Pin Contact Assembly
Verify perforated insert is present prior
to crimping contact assembly. Crimp will
not function properly without insert.
CAUTION
!
Figure 4 (See Paragraph 3.5.2)
6 of 12
Tyco Electronics Corporation
Rev B
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
conditions shown in the “ACCEPT” column.
“REJECT” terminals, splices, and contacts can be
avoided through careful use of the tabular information
in Figure 2A or 2B and the instructions Section 3, and
by performing regular die maintenance as instructed
in Section 5.
4. CRIMP INSPECTION for COPALUM Terminals and
Splices (Figure 5A) and HF-30 Pin and Socket Contacts
(Figure 5B)
Inspect crimped contacts by checking the features
described in Figure 5A or 5B as applicable. Use only
the terminals, splices, and contacts that meet the
COPALUM Terminals and Splices
ACCEPT
REJECT
3
4
5
1
Wire Range
Stamped Here
Terminal
2
6
4
1
2
1
Wire Range
Stamped Here
3
1
1
Parallel
Splice
4
4
5
5
1
4
1
Butt Splice
1
3
4
2
Wire Range
Stamped Here
2
Wire Range
Stamped Here
3
1
2
Crimped off end of splice or terminal.
Crimps centered. Crimp may be slightly off center BUT
NOT OFF END OF WIRE BARREL.
1
2
CMA of wire being used does not match wire range
stamped on terminal, splice, or dies.
CMA of wire being used matches wire range specified
for each terminal dash number.
Insulation entered barrel of terminal or splice. CHECK
FOR INCORRECT STRIP LENGTH.
Wire not inserted far enough in terminal or splice. End
of wire must be visible through inspection hole of butt
splices, and be flush with or extend slightly beyond
end of terminal wire barrel or parallel splice.
3
4
3
4
Insulation does not enter wire barrel.
Wire is visible through inspection hole of butt splice,
and is flush with or extends slightly beyond end of
terminal wire barrel.
Excessive “flash” indicates wrong wire, terminal,
splice, or die combination was used.
5
6
On parallel splices, bare wire ends must be flush with
or extend slightly beyond end of barrel.
5
Nicked or missing strands.
Figure 5A
(Crimp Inspection Criteria for COPALUM Terminals and Splices)
Rev B
Tyco Electronics Corporation
7 of 12
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
HF-30 Pin and Socket Contacts
ACCEPT
1
6
Cutout for Housing Latch
Bottom View
3
Top View
Housing Stop
Cutout for Housing Latch
7
1
Bottom View
3
Top View
Cutout for Housing Latch
Crimps centered. Crimp may be slightly off center BUT
NOT OFF END OF WIRE BARREL.
1
3
Insulation does not enter wire barrel. No nicked,
missing, or broken wire strands.
Cutout for Housing Latch
Crimp die embossment, and wire size agree
with table in Figure 2. The verification of the
correct terminal dash number used with proper
crimp die and wire size must be done prior to
crimping of contacts. See Paragraph 3.5.1.
6
Crimp die embossment, and wire size agree
with table in Figure 2. The verification of the
correct terminal dash number used with proper
crimp die and wire size must be done prior to
crimping of contacts. See Paragraph 3.5.1.
7
Figure 5B
(Crimp Inspection Criteria for HF--30 Pin and Socket Contacts)
8 of 12
Tyco Electronics Corporation
Rev B
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
2. Inspect the crimp area for flattened, chipped,
cracked, worn, or broken areas. If damage is
evident, the dies must be replaced or repaired.
Examples of possible damaged die closure
surfaces are shown in Figure 6. If desired, you
may return them to Tyco Electronics for evaluation
and repair (see Section 6, REPAIR).
5. MAINTENANCE/INSPECTION
AVOID PERSONAL INJURY; exercise extreme
DANGER
caution when using power unit. Avoid depressing
foot switch or trigger control when installing or
removing die assemblies.
Customer--replaceable parts are listed in Figure 9.
A complete inventory should be stocked and
controlled to prevent lost time when replacement of
parts is necessary.
Pitted
Crimping Die Assemblies are inspected before
shipment. Tyco Electronics recommends that the die
assembly be inspected immediately upon arrival at
your facility to ensure that it has not been damaged
during shipment.
5.1. Daily Maintenance
It is recommended that each operator of the tool be
made aware of -- and responsible for -- the following
three steps of daily maintenance:
1. Remove dust, moisture, and other contaminants
with a clean brush, or a soft, lint--free cloth. Do
NOT use objects that could damage the dies.
Broken Corner
2. Make certain the dies are protected with a THIN
coat of any good SAE 20 motor oil. DO NOT OIL
EXCESSIVELY.
Figure 6
B. Gaging the Crimping Chamber
Wipe excess oil from tool, particularly from
crimping area. Oil transferred from the crimping
area onto certain terminations may affect the
electrical characteristics of an application.
NOTE
This inspection requires the use of a plug gage
conforming to the diameters provided in Figure 7.
Tyco Electronics does not manufacture or market
these gages. The following procedure is
i
recommended for inspecting the die closures.
3. When the dies are not in use, mate them and
store the tool in a clean, dry area.
1. Clean oil or dirt from the die closure areas, and
plug gage elements.
5.2. Periodic Inspection
2. Assemble and adjust dies to meet the “gage
dimension” indicated in Figure 8, Detail A.
Tyco Electronics recommends that a maintenance
and inspection program be performed periodically to
ensure dependable and uniform terminations. Though
recommendations call for at least one inspection a
month, frequency of inspection depends on:
3. With dies positioned at the “gage dimension,”
inspect the bar crimp closure using the proper plug
gage. Align the GO element of the gage with the
crimping chamber. Push the element straight into
the chamber without using force. The GO element
must pass completely through the crimping
chamber without using force, as shown in Figure 8,
Detail A.
1. The care, amount of use, and handling of the
dies.
2. The presence of abnormal amounts of dust and
dirt.
4. Align the NO--GO element with the crimping
chamber and try to insert it straight into the
chamber. The NO--GO element may start entry,
but must not pass through, as shown in Figure 8,
Detail A.
3. The degree of operator skill.
4. Your own established standards.
A. 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 material.
5. With dies positioned at “gage dimension,” check
the right and left rectangular crimp closures using
the proper plug gage in the same manner as Steps
4 and 5; see Figure 8, Detail B.
Rev B
Tyco Electronics Corporation
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408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
Suggested Plug Gage Design - Bar Crimp
Suggested Plug Gage Design - Rectangular Crimp
GO Dim.
NO -GO Dim.
GO Dim.
“B” Dia.
NO -GO Dim.
“B” Dia.
“G” Dia.
“G” Dia.
Bar Crimp
Rectangular
Crimp Closure
Configuration
Closure
Configuration
50.8 [2.00]
Min. Typ.
50.8 [2.00]
Min. Typ.
GAGE ELEMENT DIMENSIONS
(“B” DIA)
GAGE ELEMENT DIMENSIONS
(“G” DIA)
DIE
SET
DIE
SET
GO
NO-GO
GO
NO-GO
5.512--5.519
[.2170--.2173]
5.763--5.766
[.2269--.2270]
12.624--12.631
[.4970--.4973]
12.977--12.979
[.5109--.5110]
68034
68035
68036
68037
68037--1
68043
68044
68045
68046
68047
68048
68049
68050
68034
68035
68036
68037
68037--1
68043
68044
68045
68046
68047
68048
68049
68050
6.172--6.180
[.2430--.2433]
6.424--6.426
[.2529--.2530]
13.945--13.952
[.5490--.5493]
14.298--14300
[.5629--.5630]
6.960--6.967
[.2740--.2743]
7.211--7.214
[.2839--.2840]
15.596--15.603
[.6140--.6143]
15.949--15.951
[.6279--.6280]
7.874--7.882
[.3100--.3103]
8.125--8.128
[.3199--.3200]
17.526--17.534
[.6900--.6903]
17.879--17.882
[.7039--.7040]
7.239--7.247
[.2850--.2853]
7.490--7.493
[.2949--.2950]
16.332--16.340
[.6430--.6433]
16.685--16.688
[.6569--.6570]
1.702--1.709
[.0670--.0673]
1.953--1.956
[.0769--.0770]
4.1191--4.199
[.1650--.1653]
4.544--4.547
[.1789--.1790]
2.007--2.014
[.0790--.0793]
2.258--2.260
[.0889--.0890]
5.258--5.265
[.2070--.2073]
5.611--5.613
[.2209--.2210]
2.464--2.471
[.0970--.0973]
2.715--2.718
[.1069--.1070]
5.715--5.723
[.2250--.2253]
6.068--6.071
[.2389--.2390]
2.718--2.725
[.1070--.1073]
2.969--2.972
[.1169--.1170]
6.629--6.637
[.2610--.2613]
6.982--6.985
[.2749--.2750]
3.404--3.411
[.1340--.1343]
3.655--3.658
[.1439--.1440]
7.925--7.932
[.3120--.3123]
8.278--8.280
[.3259--.3260]
3.835--3.843
[.1510--.1513]
4.087--4.089
[.1609--.1610]
8.865--8.872
[.3490--.3493]
9.218--9.220
[.3629--.3630]
4.343--4.351
[.1710--.1713]
4.595--4.597
[.1809--.1810]
9.881--9.888
[.3890--.3893]
10.233--10.236
[.4029--.4030]
4.8511--4.859
[.1910--.1913]
5.103--5.105
[.2009--.2010]
11.201--11.209
[.4410--.4413]
11.554--11.557
[.4549--.4550]
Figure 7
If both the bar crimp and the rectangular crimp
closures meet the plug gage conditions, the closures
may be considered dimensionally correct and should
be 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 6, REPAIR.
For additional information concerning the use of the
plug gage, refer to Instruction Sheet 408--7424.
10 of 12
Tyco Electronics Corporation
Rev B
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
Inspection of Bar Crimp Closure Inspection of Rectangular Crimp Closure
Detail A
Left Die
Closure
Detail B
Right Die
Closure
Gage Dimension:
42.27 [1.664] for 8-3/0 Sizes
74.3 [2.925] for 4/0-500 MCM Sizes
Radius of
Bar Crimp
“GO” Gage Must Pass Completely
Through the Die Closure
“GO” Gage Must Enter
to Radius of Bar Crimp
“NO -GO” Gage May Enter Partially, but Must
Not Pass Completely Through the Die Closure
“NO -GO” Gage May Enter Partially, but
Must Not Enter to Radius of Bar Crimp
Figure 8
6. REPAIR/REPLACEMENT
7. REVISION SUMMARY
Replaceable parts are listed in Figure 9. Parts other
than those listed in Figure 9 should be replaced by
Tyco Electronics to ensure quality and reliability of the
tool. Order replacement parts through your Tyco
Electronics Representative, or call 1--800--526--5142,
or send a facsimile of your purchase order to
1--717--986--7605, or write to:
S Updated document to corporate requirements
S Added new part number 68037--1 to tables in
Figures 1, 2, 7, and 9
S Added, deleted, or changed text in Section 2,
Paragraphs 3.1.1, 3.1.2 CAUTION, 3.2
DANGER, 3.2.1, 3.2.2, and SubHeadings 3.2,
3.3, and 3.4
S Deleted old and added new artwork to Figure 2
S Added new Paragraph 3.5.1 and renumbered
S Added new Figure 4 and renumbered
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
S Added new callouts to Figures 1, 2B, 3, and
deleted callout and added text to Figure 5B
S Combined Figures 6 and 7 and renumbered
For tool repair service, please contact an Tyco
Electronics Representative at 1--800--526--5136.
Rev B
Tyco Electronics Corporation
11 of 12
408-2353
Die Assemblies for COPALUM Terminals and Splices and HF-30 Pin and Socket Contacts
2
1
ITEM 1
ITEM 2
ASSEMBLY
MOVING DIE (INDENTER)
1--307586--3
1--307586--4
1--307586--5
1--307586--6
1--307586--7
307586--1
STATIONARY DIE (NEST)
1--307585--3
1--307585--4
1--307585--5
1--307585--6
1--307585--7
307585--1
68034
68035
68036
68037
68037--1
68043
68044
68045
68046
68047
68048
68049
68050
307586--2
307585--2
307586--3
307585--3
307586--4
307585--4
307586--5
307585--5
307586--6
307585--6
307586--7
307585--7
307586--8
307585--8
Figure 9
12 of 12
Tyco Electronics Corporation
Rev B
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