Instruction Sheet
AMPOWER* Crimping Die Assemblies
408-2710
68361-1, 68253-1, 68304-1, and 59867-1
18 Mar 11 Rev G
2. DESCRIPTION
DYNA-CRIMP*
Crimping Head 69099
Lockscrew Each die assembly features a stationary die, a moving
die, and a locator assembly (refer to Figure 1). Both
the stationary and moving die have a shank (with a
Flat on flat) which is used to align and secure each die in the
Shank crimping head. The locator assembly is used to aid in
positioning the terminal in the stationary die.
Stationary
3. CRIMPING PROCEDURE
Die
Install the dies according to the instructions contained
Locator in 408-2458. Refer to the table in Figure 2 and select
Assembly
the appropriate terminal and wire. Ensure that wire
size stamped on terminal corresponds with wire size
stamped on dies. Strip the wire to the length indicated.
Do NOT cut or nick the wire strands.
Refer to Figure 3 and proceed as follows:
To avoid personal injury when operating power unit,
DANGER
exercise caution when holding terminals or wires
STOP near crimping area.
Ram Lockscrew Moving Die
1. Position terminal in stationary die so that large,
flat surface of terminal is parallel to and resting
Figure 1 against angular surface of locator.
2. Hold the terminal in position and activate power
1. INTRODUCTION
unit so that moving die advances just enough to
AMPOWER Crimping Die Assemblies 68361-1, hold terminal in place. Do not deform terminal wire
68253-1, 68304-1, and 59867-1 (shown in Figure 1) barrel.
are designed for use in DYNA-CRIMP Crimping Head
69099, which is hydraulically activated by Hydraulic
Power Unit 69120-[ ] or Hydraulic Hand Pump
Terminal
314979-1. Each die assembly, when installed in the
crimping head, will crimp AMPOWER Quick-
Disconnect Terminals onto standard wire sizes as
listed in Figure 2. Read these instructions thoroughly
before using the dies.
These instructions provide specific information
Wire Strip
regarding the die assemblies and applicable terminals.
Length
For information regarding die insertion/removal and
general operation of the DYNA-CRIMP Crimping
Head, refer to instruction sheet 408-2458. For
WIRE
DIE
information on the Hydraulic Power Unit, refer to
TERMINAL
STRIP LENGTH SET
customer manual 409-1950 and for information on the
NUMBER
SIZE
NUMBER
Hydraulic Hand Pump, refer to 409-5860.
MIN. MAX.
Reasons for reissue are provided in Section 6,
52594-1, 52594-3,
1/0 68361-1
REVISION SUMMARY.
and 52594-3
29.46 30.99
2/0 52595-1 68253-1
Dimensions in this instruction sheet are in metric
NOTE [1.16] [1.22]
units [with U.S. customary units in brackets].
3/0 52596-1 59867-1
Figures are not drawn to scale.
4/0 53631-1 68304-1
i
Figure 2
2011 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change.
1 of 5
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LOC B408-2710
4.1. Daily Maintenance
1. Remove dust, moisture, and other contaminants
Flat Surface of
with a clean brush, or a soft, lint-free cloth. Do NOT
Terminal Rests
use objects that could damage the dies.
Against Locator
2. All surfaces should be protected with a thin coat
of any good SAE 20 motor oil. Do not oil
excessively.
Quick-Disconnect
Guide Pins Must
3. When the dies are not in use, store them in a
Be on this Side of
clean, dry area.
Locator
4.2. Lubrication
To protect dies from rust when storing, lubricate all
surfaces with SAE 20 motor oil. Before using dies,
wipe off excess oil, particularly from crimping area. Oil
transferred from the crimping area onto certain
Moving Die
terminations may affect the electrical characteristics of
the termination.
Figure 3
4.3. Periodic Inspection
3. Insert stripped wire all the way into terminal wire
1. Remove accumulated dirt, grease, and foreign
barrel.
matter by immersing the dies in a suitable
commercial degreaser that will not affect paint or
4. Hold the wire in place and activate power unit
plastic material.
through a complete cycle.
2. Inspect die crimp area for worn, cracked, or
5. Allow the dies to open fully, then remove the
broken surfaces. If damage is evident, return the
crimped terminal.
dies to TE for evaluation and repair. See Section 5,
Inspect crimped terminals by comparing them to the
REPLACEMENT AND REPAIR.
ones shown in Figure 4. Use only the terminals that
meet the conditions shown in theACCEP column.
4.4. Crimping Die Closure InspectionREJEC terminals can be avoided by carefully
This inspection requires the use of a plug gage
following the above procedures and by performing
conforming to the dimensions shown in Figure 5.
regular tool maintenance, as provided in Section 4,
TE does not manufacture or market this gage.
MAINTENANCE AND INSPECTION PROCEDURE.
To gage die closure, refer to Figure 6 and proceed as
4. MAINTENANCE AND INSPECTION PROCEDURE
follows:
It is recommended that a maintenance and inspection
1. Remove dies from crimping head.
program be performed periodically to ensure
2. Remove traces of oil or dirt from the crimping
dependable and uniform terminations. Frequency of
chambers and plug gage.
inspection depends on:
3. Assemble and adjust dies to meet thegage
The care, amount of use, and handling of the dies.
dimensio indicated in Figure 6.
The presence of abnormal amounts of dust and
4. Align the GO element with the wire barrel
dirt in your facility.
crimping chamber. Push element straight into the
The degree of operator skill.
crimping chamber without using force. The GO
Your own established standards. element must pass completely through the crimping
chamber.
The dies are inspected before being shipped;
5. Check the wire barrel crimping chamber with the
however, it is recommended that the dies be inspected
NO-GO element in the same manner as step 4. The
immediately upon their arrival at your facility to ensure
NO-GO element may start entry, but must not pass
that there was no damage during shipment. Due to the
completely through the crimping chamber.
precision design, it is important that no parts of these
dies be interchanged except those replacement parts
listed in Figure 7.
Rev G 2 of 5