408-10210

Crimping Die Assemblies for COPALUM Sealed Terminals and Splices

5 of 8

Rev A

Tyco Electronics Corporation

Figure 6

Anvil

Nest

Edge of Die is

Positioned

Within Width of

Splice Crimp Mark

Splice Crimp

Marks

Anvil

Wire

Stripe Marking

Must be on Top

Dot

Nest

Splice Detail

View

Stripe Marking Must

be on Top

View

Do NOT turn or twist the wire/splice during

insertion.

When using splices with a color coded band

around end of splice, use correct copper

conductors in the color coded end.

4. Holding wire in place, activate power unit again

to complete crimp.

5. When crimp is completed, remove the splice.

If splice sticks in die after crimping, apply a

rocking action to remove it from the die. Wipe

light oil on dies to reduce sticking, or use spray

dry lubricant.

6. To crimp other half of splice, rotate the

splice/tool 180

_, making sure the stripe marking on

splice is inside the assembly, facing up, and in

alignment with dot on nest. See Figure 6. Follow

the same procedure used to crimp first side of

splice (Steps 1 through 5).

4. CRIMP INSPECTION MARK

A crimp inspection mark is featured on each crimped

terminal or splice. The mark consists of a dimple on

the face of a cylinder which is embossed in the

primary crimp area of the terminal or splice. The

inspection mark must appear as shown in the artwork

presented in Section 3.5 of Application Specification

114–2134.

The inspection mark must appear as indicated in

Application Specification 114–2134, in order to qualify

the terminal or splice as an acceptable termination.

The terminal or splice is unacceptable and should be

rejected if the identification mark is deformed.

If the mark is deformed, refer to Figure 3 of this

instruction sheet to verify proper wire CMA and

terminal/die combination.

Verify that crimping dies fully bottom during crimp

cycle. Also, determine if dies are in proper

configuration by gaging the crimp chamber specified

in Paragraph 5.2.B.

5. MAINTENANCE/INSPECTION

To avoid personal injury, always disconnect

electrical and/or air supply to power unit before

performing, adjustments, inspections, and

repairs.

These instructions have been approved by Tyco

Electronics Design, Production, and Quality Control

Engineers to provide documented maintenance and

inspection procedures. Through Tyco Electronics test

laboratories and the inspection of production

assembly, the procedures described herein have

been established to ensure the quality and reliability

of crimping die assemblies.

Customer–replaceable parts are listed in Figure 7. A

complete inventory should be stocked and controlled

to prevent lost time when replacement of parts is

necessary.

Die assemblies are inspected before shipment. It is

recommended that the die assembly be inspected

immediately upon arrival at your facility to ensure that

it has not been damaged during shipment.

CAUTION

!

NOTE

i

NOTE

i

DANGER