Crimping Die Assemblies for
COPALUM* Terminals and Splices
and HF- 30 Pin and Socket Contacts
Instruction Sheet
25 MAR 10 Rev B
408-- 2353
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
68034 68035 68036
68037 68037--1 68050
CRIMPING HEAD
69099, 1752868-- 1
68043 68044 68045
68046 68047
68048 68049
Figure 1
Flats on Shank
Moving Die
(Indenter)
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.
See Section 7, REVISION SUMMARY, for revision
information.
NOTE
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.
aluminum or copper{ wire and HF--30 Pin and Socket
Contacts for stranded aluminum and copper wire
sizes specified in Figure 2B.
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
DANGER
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.
i
The radii of both dies must match the radii of the tool.
See Figure 1.
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.
Proceed as follows:
1. Loosen retaining screw in top section of
crimping head. See Figure 1.
2. DESCRIPTION
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,
{Butt
Splices Only. Refer to Paragraph 3.3
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2010
Tyco Electronics Corporation, Berwyn, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
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LOC B
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.
NOTE
Ensure that the dies are inserted fully and that
the “flats” on shanks are facing the operator.
408- 2353
See Figure 2A for COPALUM Terminal and Splices
or Figure 2B for HF--30 Pin and Socket Contacts.
2. Strip wire to dimension indicated in Figure 2A
for COPALUM Terminals and Splices or Figure 2B
for HF--30 Pin and Socket Contacts.
CAUTION
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.
i
DANGER
3. Activate power unit to advance ram until
setscrew is visible.
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.
5. Activate power unit to complete cycle and allow
ram to return to down position.
3.2. Crimping COPALUM Terminals
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.
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 installing or
removing die assemblies.
1. Ensure that the wire size stamped on the
terminal corresponds with the size marked on the
dies.
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.)
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.
CRIMPING
DIE ASSY
68043
68044
68045
68046
68047
68048
68049
68050
68034
68035
68036
68037
CRIMPING
HEAD
3. WIRE STRIPPING AND CRIMPING PROCEDURE
3.1. Wire Stripping Procedure
1. Select the proper size terminal, splice, or HF--30
pin and socket contact for the wire size being used.
WIRE
SIZE
8
6
4
2
1/0
2/0
3/0
4/0
250 MCM
300 MCM
400 MCM
500 MCM
mm
2
6.638 -- 10.540
10.540 -- 16.772
16.772 -- 26.652
26.652 -- 42.412
42.412 -- 60.55
60.55 -- 76.26
76.26 -- 96.27
96.27 -- 117.049
117.049 -- 152.01
152.01 -- 192.55
192.55 -- 242.20
242.20 -- 304.02
CMAD RANGE
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
i
WIRE STRIP LENGTH
MIN
MAX
10.32 [.4062]
10 32 [ 4062]
14.29 [.5625]
11.90 [.4687]
11 90 [ 4687]
15.88 [.6250]
69099
1752868--1
18.25 [.7187]
18 25 [ 7187]
19.10 [.75]
28.58 [1.125]
31.75 [1.250]
34.93 [1.375]
38.1 [1.50]
19.84 [.7812]
19 84 [ 7812]
20.64 [.8125]
31.75 1.250
34.93 [1.375]
38.1 [1.50]
41.28 [1.625]
69082
1752786--1
DCircular
Mil Area
Figure 2A
(For Crimping COPALUM Terminals and Splices - See Paragraphs 3.2, 3.3, and 3.4)
-
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Tyco Electronics Corporation
Rev
B
Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts
HF-- 30 Socket
Contact Assembly
408- 2353
Nest (Stationary Die)
2
Part Number,
Revision
Information
1
HF-- 30 Pin Contact Assembly
Ensure Terminal Dash Number Identifier
Stamped on Terminal Agrees with Crimp
Die Assembly Part Number and Wire
Size Prior to Crimping
WIRE STRIP
LENGTH
(mm)
MIN
23.4
23.4
25.9
25.9
29.7
29.7
29.7
29.7
MAX
26.6
26.6
29.1
29.1
32.9
32.9
32.9
32.9
Indenter (Moving Die)
SWIRE
SIZE
(mm
2
)
185
150
240
185
300
240
400
300
WIRE
TYPE--
Alum
Copper
Alum
Copper
Alum
Copper
Alum
Copper
STAMPED
WIRE AREA
(mm
2
)
185
150
240
185
300
240
400
300
NOMINAL
WIRE
CMA
365,102
296,029
473,646
365,102
592,058
473,646
789,410
592,058
SCRIMPING
DIE
ASSY.
ASSY
------z
------z
------z
------z
68037--1zz
68037--1zz
68037zz
68037zz
STERMINAL
DASH NO.
IDENTIFIER
--1
--1
--2
--2
--3
--3
--4
--4
SCRIMPING
DIE
EMBOSSMENT
IDENTIFIER
300
300
400
400
600
600
500
500
CRIMPING
HEAD
69082
1752786--1
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.
zz
Pending
product qualification approval.
Figure 2B
(For Crimping HF-
-30 Pin and Socket Contacts - See Paragraph 3.5)
-
Stationary Die
Detail A
COPALUM
Terminal
Center Wire
Barrel in Die
Detail B
COPALUM
Butt Splice
View Port Faces
Stationary Die
End of Splice
Flush with
Side of Die
Top of Terminal
Tongue Faces
Moving Die
End of Wire Must be Flush
with or Extend Beyond End
of Wire Barrel
Moving Die
End of Wire
Butts Against
Wire Stop
Figure 3 (cont’d)
Rev
B
Tyco Electronics Corporation
3
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Die Assemblies for COPALUM Terminals and Splices and HF- 30 Pin and Socket Contacts
Detail C
COPALUM
Parallel Splice
Ends of Wires Must be
Flush with or Extend
Beyond Ends of Splice
408- 2353
Center
Splice in
Die
Same Criteria Applies
Hydraulic Crimp Head
Stationary Die (Nest)
End
of Barrel Flush
with Edge of Die
Detail D
HF--30 Contact
Pin Contact
Assembly HF-- 30
to Pin Contact
Socket Contact
Assembly HF-- 30
Moving Die
(Indenter)
Wire
inserted fully into contact
until insulation bottoms on edge
of contact. No wire strands
should be visible.
Housing Stop on
Bottom
Detail E
HF-- 30 Contact Location
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
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.
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.
5. Activate power unit to complete crimp.
6. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
408- 2353
3.4. Crimping Procedure (COPALUM Parallel Splices)
1. Center parallel splice in stationary die 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 terminal or splice sticks in die after crimping,
apply rocking action to remove from die.
3.3. Crimping Procedure (COPALUM Butt Splice)
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.
2. Activate power unit so that moving die advances
and holds splice in place. Do NOT deform splice
wire barrel.
3. Insert stripped wire into splice wire barrel until
end of wire butts against wire stop as shown in
Figure 3, Detail B.
NOTE
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
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
cross--sectional area must be within the CMA
range listed for the splice in Figure 2.
i
5. Refer to Figure 5A and Section 4, CRIMP
INSPECTION.
3.5. Crimping Procedure (HF- 30 Pin and Socket
Contacts)
1. Ensure the terminal dash number, crimp die
assembly, and wire size agree with table in
Figure 2B prior to crimping.
2. Visually inspect contacts for presence of insert.
See Figure 4.
DANGER
Verify perforated insert is present prior to
crimping contact assembly. Crimp will not
function properly without insert.
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.
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.
NOTE
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.
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.
i
7. Refer to Figure 5B and Section 4, CRIMP
INSPECTION.
Rev
B
Tyco Electronics Corporation
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