408-2281

Rev CK

2 of 12

1. INTRODUCTION

The crimping die assemblies are designed to be installed into the hydraulic crimping heads listed in Table 1

and are used to crimp COPALUM sealed terminals and splices. Read these instructions thoroughly before

crimping any terminals or splices.

Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY.

NOTE

Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Illustrations are for reference only and are not

drawn to scale.

2. DESCRIPTION

Each crimping die assembly consists of a stationary die (nest) and moving die (anvil). Each die features an

alignment dot on the front of the die. See Figure 1.

3. DIE ASSEMBLY INSTALLATION

For information concerning die installation and general performance of the hydraulic crimping head, refer to the

instruction sheet packaged with the crimping head.

DANGER

To avoid personal injury, ALWAYS DISCONNECT electrical and air supply to power unit before installing the hydraulic

crimping head or die assembly.

In order to achieve proper mating of the dies during installation, ensure that:

— the shanks of the dies are offset to the same surface of the die, but that the alignment dots align and

face the operator

— the anvil moves and the nest is stationary

CAUTION

DO NOT mix dies from different or the same die assemblies (because of inconsistent wearing)

— it is important that the dies

are used as the set.

DANGER

To avoid personal injury, make sure to close the yoke of the hydraulic crimping head and fully insert the pin. When operating

the power unit, be careful when handling terminals, splices, or wire near the crimping area of the die assembly.

4. CRIMPING PROCEDURE

Select the die assembly and terminal or splice, and prepare the wire as follows:

1. Refer to Figure 2/Table 2 to select the appropriate die assembly and terminal or splice according to

the wire.

NOTE

For aluminum-to-aluminum application, butt splices will accept the same wire size at either end. For aluminum-to-copper

application, the copper wire size must be smaller to compensate for differences in the electrical properties of copper and

aluminum. This also applies when using copper wire in a terminal as listed in Table 2.

2. Cut the end of the wire perpendicular to the wire; DO NOT distort the shape of the wire. It is

recommended to chamfer the edge around the group of wires. See Figure 2. The chamfer will aid in

the insertion of the wire into the terminal or splice.

3. Strip the wire to the length indicated in Figure 2/Table 2. DO NOT nick or cut the wire strands. The

strip length for the wire will depend on the number of insulation layers covering the wire.

There are two approved methods for crimping the terminals and splices using these die assemblies and

hydraulic crimping heads. Proceed as follows: