Instruction Sheet AMPOWER* Disconnect 408-2292-3 Terminal Crimping Dies 12 JUL 13 Rev B NOTE NOTE All dimensions on this document are in metric units with i Lock Screw U.S. customary units in brackets . Figures and illustrations are for identification only and are not drawn Typical Dies to scale. (1/0 Thru 400 MCM) Reason for revision is provided in Section 5, REVISION SUMMARY. Stationary Die Moving Die Lock Screw 2. CRIMPING PROCEDURES in Ram NOTE NOTE i Crimping Head No. 69082 is illustrated throughout this document, however, crimping instructions are the same for 69082, 69099, 1752786-1, or 1752868-1 crimping heads. 2.1. Die Insertion Flats on Shank DANGER Typical Dies Avoid personal injury, when using power unit, exercise (500-777 MCM) caution to avoid accidentally depressing the foot pedals or trigger control when changing dies. AMPOWER DISCONNECT TERMINAL CRIMPING DIES USED IN CRIMPING HEAD USED IN CRIMPING HEAD 1. Select the correct dies for wire size being used. 69082 or 1752786-1 69099 or 1752868-1 See Figure 2. 46753-3 2. Loosen the lock screw in the top section of the 46758-2 68200-1 crimping head. See Figure 1. 46758-3 68201-1 68204-1 3. Insert the shank of the stationary die into the top 68203-1 68206-1 section of the crimping head and tighten the lock 68332-1 screw. See Figure 1. Figure 1 NOTE NOTE i Ensure the dies are inserted fully nd flats on the 1. INTRODUCTION shanks are facing the lock screws. This instruction sheet provides information on product 4. Activate the power unit, advance the ram until the application and a maintenance and inspection lock screw is visible procedure for AMPOWER Disconnect Terminal 5. Loosen the lock screw and insert the shank of the Crimping Dies listed in the table in Figure 1. moving die into the ram. Tighten the lock screw. See These crimping dies are used to crimp AMPOWER Figure 1. Quick Disconnect Terminals on wire sizes No. 1/0 6. Active the power unit to complete the cycle and through 777 MCM. allow the ram to return to the Down position. Basic instructions on the use of the dies, wire NOTE preparation, etc., are provided in Section 2, NOTE i Observe that the shanks are offset on the 500, 600, and INSTRUCTIONS. Section 3 features a terminal Crimp 777 MCM moving and stationary dies. Ensure that the Inspection procedure, and Section 4 contains shank of each die is offset to the same side in order to Maintenance and Inspection Procedures which will maintain the proper mating of dies. enable you to maintain a die certification program. The dies are coated with preservative to prevent rust 2.2. Die Removal and corrosion. Wipe this preservative from the dies, 1. Loosen the lock screw in the top section of the particularly from the crimping areas. crimping head and remove the stationary die. For further instructions relative to the hydraulic power 2. Advance the ram until the lock screw is visible. unit and hydraulic crimping heads, refer to the Loosen the lock screw and remove the dies. instructions packaged with these tools. 2013 Tyco Electronics Corporation, a TE Connectivity Ltd. company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS408-2292-3 WIRE STRIP LENGTH WIRE DIE SET CRIMPING HEAD SIZE NUMBER NUMBER MINIMUM MAXIMUM 1/0 68200-1 69099 23.82 .938 25.4 1.000 2/0 68201-1 69099 23.82 .938 25.4 1.000 250 MCM 68203-1 69099 39.67 1.562 41.28 1.625 350 MCM 68204-1 68082 39.67 1.562 41.28 1.625 400 MCM (2 Crimps) 68332-1 68082 44.45 1.750 46.02 1.812 500 MCM (2 Crimps) 68206-1 68082 44.45 1.750 46.02 1.812 600 MCM (2 Crimps) 46757-3 68082 50.8 2.000 52.37 2.062 777 MCM (2 Crimps) 46758-2, 46758-3 68082 50.8 2.000 52.37 2.062 Figure 2 2.3. Wire Stripping and Crimping Procedures A DANGER 1/0 Avoid personal injury. When operating power unit, exercise caution while holding terminals or wire near crimping area. A. Wire Stripping Procedure 1. Select the proper size terminals and die set for the wire size being used. See Figure 2. 2. Strip the wire to the dimensions indicated in Figure 2. CAUTION Do NOT nick or cut conductor strands. B. Crimping Procedures (Single Crimp) 1/0 Through 350 MCM Terminals (Figure 3) 1. Ensure the wire size stamped on the terminal corresponds with the wire size stamped on the dies. B 2. Orient the 1/0 terminal with the dies so the large 400 MCM slot in the terminal is rotated 30 to 60 from the vertical as shown in Figure 3A. Orient the 250 MCM and 350 MCM terminals with the dies so that the large slot in the terminals is rotated 45 from the vertical as shown in Figure 3A. 3. Position the terminals so the dies are centered on the wire barrels of the terminals as shown in Figure 3A. 4. Activate the power unit so the moving die advances and holds the terminal in place. Do NOT deform the terminal. 5. Insert a stripped wire all the way into the terminal wire barrel. Activate the power unit to complete the crimp. 6. Refer to Section 3 and Figure 5 for crimp inspection. C. Crimping Procedures (Dual Crimp) 400 MCM Terminals (Figure 3) 1. Ensure the wire size stamped on the terminal corresponds with the wire size stamped on the dies. Figure 3 Rev B 2 of 6