Instruction Sheet

Insulation Piercing

COPALUM* Terminal and

408-2433

(was IS 2433)

LOC B

1 of 8

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

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

21 JAN 09 Rev A

SpliceCrimping Heads

1. INTRODUCTION

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.

Do not use stranded aluminum wire.

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.

All dimensions in this document are in millimeters

[with inches in brackets]. Figures and Illustrations

are for reference only and are not drawn to scale.

Reasons for reissue are provided in Section 5,

REVISION SUMMARY.

2. INSTRUCTIONS

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.

2.1. Crimping Head Installation

Disconnect tool from air supply.

1. Select the correct crimping head for the wire

size being used. Wire size and the insulation

piercing crimp symbol (

Y) appear on one jaw as

shown in Figure 1.

Figure 1

Toggle Lever Shank

Thumb Control

Assembly

Pins

Release Lever

Toggle Arm

Mounting Lugs

Link(s)

Wire Size Plus

Crimp Symbol

Appear on

Surface of Anvil

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.

5. Insert assembly pins.

6. Connect air supply to tool 586 to 689 kPa

[85 to 11 psi].

7. Tool is now ready for operation.

2.2. Crimping Head Removal

Disconnect tool from air supply.

1. Remove assembly pins.

2. Lower head away from mounting lugs, twist

head 90

° and remove from toggle arm.

3. Reinstall assembly pins.

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:

NOTE

i

NOTE

i

DANGER

CAUTION

!

CAUTION

!