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Technical Document


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1 of 17
© 2015 TE Connectivity family of companies
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
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.te.com.
Instruction Sheet
408-32087
26 JUN 15 Rev K
CRIMPING
DIE ASSEMBLY
HYDRAULIC CRIMPING HEAD
(Instruction Sheet)
68006-3
68007-3
68008-3
68009-3
68010-3
69066 (408-2453)
58422-1 (408-9535)
1752787-1 (408-8914)
1752877-1 (408-8956)
---
59877-3
68011-3
314948-3
58422-1 (408-9535)
1752787-1 (408-8914)
Figure 1
1. INTRODUCTION
The crimping die assemblies are designed to be installed into the hydraulic crimping heads listed in Figure 1
and are used to crimp pre-lubed COPALUM Lite sealed terminals and splices shown in Figure 2. The supports
are designed to minimize crimp barrel and wire angle after crimping.
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 and figures 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), a nest wire support, an
anvil wire support, and an anvil tongue support used only with 59877-3, 68009-3, 68010-3, 68011-3, and
314948-3. See Figure 1. The anvil tongue support is not used with 68006-3, 68007-3, 68008-3 die sets.
3. INSTALLATION
3.1. Support Installation
DANGER
To avoid personal injury, install the supports on the die outside of the crimping head. ALWAYS DISCONNECT electrical and
air supply to the power unit before installing the hydraulic crimping head or supports.
Crimping Die Assemblies and
Supports for COPALUM* Lite
Sealed Terminals and Splices
Shank
Nest Wire
Support
Stationary
Die (Nest)
Tongue Support (Used
ONLY with 59877-3,
68009-3, 68010-3,
68011-3, and 314948-3)
Anvil Wire
Support
Moving
Die Anvil
Support Mounting
Screw
Shank
ORIGIN
AL INSTRUCTIONS
408-32087
Rev K
2 of 17
Figure 2
The supports can be placed on the dies and removed as needed.
Each support is keyed to fit only where it is intended. To install a support, align the pins on the support with the
pin holes on the die and tighten the support mounting screw. To remove a support, fully loosen the support
mounting screw and pull the support away from the die.
DANGER
Installing the supports on dies will extend the pinch areas of the dies. BE SURE to keep hands and fingers clear of the
supports while crimping. If necessary, use soft jaw pliers to grip the terminal tongue being careful not to impart damage.
3.2. 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 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 PRODECURE
4.1. Selection
1. Refer to Figure 3 and select the appropriate die assembly and terminal or splice according to the wire.
NOTE
Butt splices will accept the same wire size at either end.
Butt Splice
Flag
Straight
Straight Dual Hole
408-32087
Rev K
3 of 17
TOOL
TERMINAL
WIRE
SIZE
(AWG)
HYDR
HEAD
DIE
SET
HYDR
PUMP
PUMP
VOLT
HYDR
PRESS
NEST
WIRE
SUPPORT
ANVIL
WIRE
SUPPORT
ANVIL
TONGUE
SUPPORT
(STRAIGHT
TONGUE)
TE PART
NO.
DESCRIPTION
8
69066
68006-3
69120-1
110
8200
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
69066
68006-3
69120-1
110
8200
2217323-1
2217324-1
---
2226092-1
Splice, Butt
8
58422-1
68006-3
69120-1
110
8200
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
58422-1
68006-3
69120-1
110
8200
2217323-1
2217324-1
---
2226092-1
Splice, Butt
8
69066
68006-3
69120-2
220
8200
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
69066
68006-3
69120-2
220
8200
2217323-1
2217324-1
---
2226092-1
Splice, Butt
8
58422-1
68006-3
69120-2
220
8200
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
58422-1
68006-3
69120-2
220
8200
2217323-1
2217324-1
---
2226092-1
Splice, Butt
8
1752877-1
68006-3
1804700-1
110
1000
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
1752877-1
68006-3
1804700-1
110
1000
2217323-1
2217324-1
---
2226092-1
Splice, Butt
8
1752787-1
68006-3
1804700-1
110
1000
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
1752787-1
68006-3
1804700-1
110
1000
2217323-1
2217324-1
---
2226092-1
Splice, Butt
8
1752877-1
68006-3
1804700-2
220
1000
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
1752877-1
68006-3
1804700-2
220
1000
2217323-1
2217324-1
---
2226092-1
Splice, Butt
8
1752787-1
68006-3
1804700-2
220
1000
2217323-1
2217324-1
---
2102568-1
Straight, Single Hole
8
1752787-1
68006-3
1804700-2
220
1000
2217323-1
2217324-1
---
2226092-1
Splice, Butt
6
69066
68007-3
69120-1
110
8200
2217323-2
2217324-2
---
2217324-2
Straight, Dual Hole
6
69066
68007-3
69120-1
110
8200
2217323-2
2217324-2
---
2217324-2
Straight, Single Hole
6
69066
68007-3
69120-1
110
8200
2217323-2
2217324-2
---
2217324-2
Splice, Butt
6
58422-1
68007-3
69120-1
110
8200
2217323-2
2217324-2
---
2217324-2
Straight, Dual Hole
6
58422-1
68007-3
69120-1
110
8200
2217323-2
2217324-2
---
2217324-2
Straight, Single Hole
6
58422-1
68007-3
69120-1
110
8200
2217323-2
2217324-2
---
2217324-2
Splice, Butt
6
69066
68007-3
69120-1
220
8200
2217323-2
2217324-2
---
2217324-2
Straight, Dual Hole
6
69066
68007-3
69120-1
220
8200
2217323-2
2217324-2
---
2217324-2
Straight, Single Hole
6
69066
68007-3
69120-1
220
8200
2217323-2
2217324-2
---
2217324-2
Splice, Butt
6
58422-1
68007-3
69120-1
220
8200
2217323-2
2217324-2
---
2217324-2
Straight, Dual Hole
6
58422-1
68007-3
69120-1
220
8200
2217323-2
2217324-2
---
2217324-2
Straight, Single Hole
Figure 3 (cont’d)
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