408-10210

Crimping Die Assemblies for COPALUM Sealed Terminals and Splices

Rev A

2 of 8

Tyco Electronics Corporation

3. Release the button and rock the die back and

forth until the nest snaps into position.

4. Activate the power unit until the lower die

release button located in the ram is exposed.

5. Depress the release button.

6. Slide the indenter into position in the ram. See

Figure 2.

7. Release the button and rock the indenter back

and forth until the die snaps into position.

8. Return ram to the down position.

2.2. Die Removal

1. Actuate the upper release button located in the

“C”–head or closed head and slide the nest out of

the head.

2. Activate the power unit until the lower die

release button (located in the ram) is exposed.

3. Depress the die release button and slide the

indenter out of the ram.

Refer to the table in Figure 3 and select the

appropriate wire, die assembly, and terminal or splice.

Strip the wire to the length indicated in the table.

DO NOT nick or cut the wire strands.

For aluminum-to-aluminum application, butt

splices will accept the same wire size at either

end. However, for aluminum-to-copper

applications, the size of the copper wire must be

decreased to a smaller size to compensate for

differences in the electrical properties of copper

and aluminum. It is also necessary to use a

smaller wire size when using copper wire in a

terminal. Refer to CMA range listed with each

wire size in Figure 3.

Wire Strip Lengths

+1.59 mm [+1/16 in.]

Butt Splice (BS)

Ring-Tongue Terminal

(RT) Single Hole

B" Equals Wire Barrel

C" Equals Insulation Barrel

Blue Ink Ring

A"

D"

D"

C"

B"

C"

B"

Copper

Side

Transitional Butt

Splice (TS)

4 Layers of

Insulation

Aluminum

Side

C"

B"

C"

B"

Ring-Tongue Terminal

(RT) Two Hole

1 or 2 Layers

of Insulation

2 Layers of

Insulation

TERMINALS (RT)

BUTT

ALUMINUM

COPPER

STRIP LENGTH

SINGLE

HOLE

DOUBLE

HOLE

BUTT

SPLICES

(BS)

and

(CMA)F

AWG

Y

and

(CMA)F

AWG

J

A

INSUL

D

COND

DIE SET

NUMBER

HEAD

NUMBER

277147-[ ]

---

277156-[ ]

8.60

(16,564)

8

4.80

(9,354)

10

22.23

[7/8]

11.11

[7/16]

1490555-1

1901821 1

277148-[ ]

55832-[ ]

277157-[ ]

14.60

(28,280)

6

8.80

(16,983)

8

22.23

[7/8]

12.70

[1/2]

1490556-1

1901821-1

1976230-1B

1490749-1

277149-[ ]

55833-[ ]

55834-[ ]s

277158-[ ]

21.90

(42,420)

4

13.80

(26,818)

6

25.40

[1]

17.45

[11/16]

1490557-1

1490749-1

FCircular Mill Area; YSee Military Specification, MIL–W–7072 for Specific Wire Requirements; JSee Military Specification, MIL–W–22759E

for Specific Wire Requirements;

sHigh Temperature Silver Plated; BCrimping Head 1976230–1 CANNOT Crimp Splices

Figure 3 (cont’d)

CAUTION

!

NOTE

i