Instruction Sheet
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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.
WIRE SIZE
(MCM)
(1)
CMA
(Circular Mil Area)
Range
Die Assembly PN
Single Crimp
Dual Crimp
350
325,000-375,000
69653
---
350 HD
400
375,000-450,000
46754-2
---
500
450,000-550,000
46755-2
---
500
---
46756-2
(2)
600
550,000-650,000
---
46756-2
600 HD
59870-1
700
650,000-750,000
---
46757-2
800
750,000-850,000
---
46758-2
900
850,000-950,000
---
46759-2
1000
950,000-1,125,000
---
46760-2
Crimping Die Assemblies 46754-2,
46755-2, 46756-2, 46757-2, 46758-2,
46759-2, 46760-2, 59870-1, and 69653
408-1602
10 NOV 16 Rev C
1
MCM equals thousand circular mils
2
After crimping, product insulation will be embossed with 600
Figure 1
1. INTRODUCTION
AMP* crimping die assemblies listed in Figure 1 are designed to crimp AMPOWER* terminals, parallel splices
and butt splices onto wire sizes 350 through 1000 MCM. The die assemblies are installed into Crimping Head
PN 69082 (Mod 1). The head is used with Hydraulic Power Units PN 69120-1 or 69120-2.
For information on tool setup and operation, refer to Instruction Sheet
Customer Manual
409-1950 for the power units.
Read these instructions carefully prior to installing, removing or using the dies.
NOTE
Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale.
Reasons for re-issue of this instruction sheet are provided in Section 8, REVISION SUMMARY.
408-2456 for the crimping head and
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408-1602
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2. DESCRIPTION
The die assemblies are either single-crimp or dual-crimp sets; each consisting of an anvil subassembly
(stationary die) and an indenter subassembly (moving die).
3. DIE INSTALLATION AND REMOVAL
DANGER
Avoid personal injury. When using power unit, exercise caution to avoid accidentally depressing foot switch or trigger control
when changing dies.
3.1. Die Installation
NOTE
Die assemblies are coated with a preservative to prevent rust and corrosion. Wipe the preservative from the dies (particularly
from the crimping areas) before installing the dies.
Refer to Figure 1 to verify that wire size to be used is compatible with die assembly. Select the proper terminal
or splice for the wire size to be used. Ensure the wire size stamped on the terminal or splice corresponds to the
wire size stamped on the stationary die. Determine the correct wire load by referring to the CMA range listed in
Figure 1. The total CMA of wires being used must be within the CMA range of the terminal or splice. Proceed
as follows:
1. Loosen the lock screw in the top of the crimping head (see Figure 2 for location).
2. Insert the shank of the stationary die into the top section of the crimping head and secure by tightening the lock screw (see Figure 2).
NOTE
Verify the die is fully inserted and that the flat area on the shank faces the lock screw.
Figure 2
3. Activate the power unit and advance the ram until the setscrew on the ram is visible.
DANGER
Take care to prevent depressing the foot switch or trigger control while installing dies or loosening or tightening setscrew.
Rev C
3 of 11
4. Loosen setscrew on ram and insert shank of moving die into the ram well. Ensure that moving die is correctly oriented with regard to stationary die, and tighten setscrew on ram (see Figure 2).
CAUTION
The shanks are offset on dual-crimp die assemblies. Take care to ensure that the shank of each die is offset to the same side
to maintain proper mating of dies.
5. Activate the power unit to complete the cycle, and allow the ram to return to the retracted position.
3.2. Die Removal
1. Loosen the lock screw in the top of the crimping head and remove the stationary die.
2. Advance the ram until the setscrew is visible. Loosen the setscrew and remove the moving die.
3. If no die assembly is to be installed following die removal, ensure that the ram setscrew is turned in far enough to avoid interfering with the movement of the ram.
4. CRIMPING PROCEDURE
4.1. Wire Preparation
Strip the wire as shown in Figure 3; taking care not to nick or cut conductor strands.
NOTE
DO NOT scale from this illustration.
Figure 3
408-1602
Rev C
4 of 11
4.2. Using Single-Crimp Die Assembly
1. Center the terminal or splice in the stationary die as shown in Figure 4.
Figure 4
408-1602
2. Activate the power unit so the moving die advances and holds the terminal or splice in place; but without deforming the wire barrel.
3. Insert the stripped wire until it bottoms in the terminal or splice.
NOTE
The end of the wire must be visible thru the sight hole.
a. For parallel splices, make sure the ends of the wires are at least flush with, or extend slightly
beyond the end of the wire barrel.
b. For butt splices, make sure the wire stop faces either die.
4. Activate power unit to complete crimp.
5. To crimp the other half of a butt splice, remove and position the un-crimped half in the stationary die. Insert wire until it bottoms against wire stop and crimp the splice.
6. Remove the terminal or splice from the dies and inspect the crimp in accordance with Section 5; CRIMP INSPECTION.
Rev C
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4.3. Using Dual-Crimp Die Assembly
Terminal and Parallel Splice
1. Place the terminal or splice in the stationary die as shown in Figure 5.
NOTE
Verify the crimp area of the dies is centered between the crimp marks of the terminal or splice.
Terminal Splice Parallel Splice
Figure 5
408-1602
2. Activate the power unit so the moving die advances and holds the terminal or splice in place without deforming the wire barrel.
3. Insert the stripped wire until it bottoms in the terminal and is visible through the sight hole.
For parallel splices, make sure the ends of the wires are at least flush with, or extend slightly beyond
the end of the wire barrel.
4. Activate power unit to complete the first crimp.
5. Remove the terminal or splice from the dies.
6. Before making the 2nd crimp, it will be necessary to turn either the terminal (or splice), the crimping head, or the dies around. Then, position the terminal or splice in the dies as shown in Figure 5 and repeat Steps 2 and 3.
7. Activate the power unit to complete the 2nd crimp.
8. Remove the terminal or splice from the dies and inspect the crimp in accordance with Section 5; CRIMP INSPECTION.
Rev C
6 of 11
Butt Splice
1. Position the butt splice so the crimp area of the die is centered within the crimp marks of the splice.
NOTE
The offset cavity of the die must always face the center of the splice, and the wire stops on the splice must always face either
die (see Figure 6).
2. Activate the power unit so the moving die advances and holds the splice in place without deforming the wire barrel.
3. Insert the first wire until it bottoms in the splice. The ends of the wires must be visible through the sight hole.
4. Activate power unit to complete the first crimp.
5. Reposition the splice as shown in Figure 6 and perform the 2nd crimp.
Figure 6
408-1602
6. Before making the 3rd and 4th crimps, it will be necessary to turn either the splice, the crimping head, or the dies, around. Then, position the splice in the stationary die as shown in Figure 6 and repeat Steps 2 and 3.
7. Activate the power unit and complete the 3rd crimp.
8. Reposition the splice as shown in Figure 6 and complete the 4th crimp.
NOTE
If the splice sticks in the die after crimping, apply a rocking action to break it free.
9. Remove the butt splice from the dies and inspect the crimp in accordance with Section 5; CRIMP INSPECTION.
Rev C
408-1602
7 of 11
Single-Crimp Die Assembly
5. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the features described in Figures 7 and 8. Use ONLY the
terminals and splices that meet the conditions shown in the “ACCEPT” column. Unacceptable terminals and
splices (depicted in the “REJECT” column can be avoided through careful use of the crimping procedure and
by performing regularly scheduled die maintenance.
Figure 7
Rev C
408-1602
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Dual-Crimp Die Assembly
Figure 8
Rev C
408-1602
9 of 11
6. MAINTENANCE AND INSPECTION
The die assembly is thoroughly inspected prior to shipment. Because of the possibility of damage in transit,
dies should be inspected upon arrival in accordance with the information provided, and at regularly scheduled
intervals thereafter to ensure conformance to standards.
6.1. Maintenance
1. The dies are coated with a preservative to prevent rust and corrosion. Wipe preservative from dies, particularly from crimping areas, prior to use.
2. Do not allow dirt, grease, or other contaminants to accumulate on the die closure surfaces. These accumulations may cause excessive wear in the die closure surfaces; thereby affecting the quality of the crimp.
3. Wipe dies frequently with a clean, soft cloth, and store them in a clean, dry area when not in use.
6.2. Visual Inspection
Visually inspect the die closure surfaces for broken, pitted, or chipped areas. Although dies may close within
permissible gage limits, worn or damaged die closure surface are objectionable and may affect the quality of
the crimp. Examples of possible damaged die closure surfaces are shown in Figure 9.
Figure 9
6.3. Gaging the Crimping Chamber
This inspection requires the use of plug gages conforming to the dimensions provided in Figure 11.
NOTE
TE Connectivity (TE) does not manufacture or market these gages.
To gage the crimping chamber, proceed as follows:
1. Remove traces of oil or dirt from the crimping chamber and plug gage.
NOTE
The ejector must be removed from the die when gaging a dual-crimp die assembly.
2. Mate the dies, then adjust them to meet the gage dimension indicated in Figure 10. Hold the dies in this position.
3. Insert GO element into the crimping chamber, but DO NOT force it. The GO element must pass through the length of the crimping chamber (see Figure 10).
4. In the same manner, try to insert the NO-GO element into the crimping chamber. The NO-GO element may enter partially, but must not pass completely thru the length of the crimping chamber (see Figure 10).
Rev C
408-1602
10 of 11
Die Assembly
Gage Element Diameter
Die Assembly
Gage Element Diameter
GO
NO-GO
GO
NO-GO
46754-2
13.564-13.571
[.5340-.5343]
13.815-13.818
[.5439-.5440]
46759-2
20.422-20.429
[.8040-.8043]
20.673-20.676
[.8139-.8140]
46755-2
15.037-15.044
[.5920-.5923]
15.288-15.291
[.6019-.6020]
46760-2
21.539-21.547
[.8480-.8483]
21.791-21.793
[.8579-.8580]
46756-2
16.612-16.619
[.6540-.6543]
16.863-16.866
[.6639-.6640]
59870-1
18.288-18.296
[.7200-.7203]
18.539-18.542
[.7299-.7300]
46757-2
17.831-17.838
[.7020-.7023]
18.082-18.085
[.7119-.7120]
69653
12.421-12.428
[.4890-.4893]
12.672-12.675
[.4989-.4990]
46758-2
19.406-19.413
[.7640-.7643]
19.657-19.660
[.7739-.7740]
Figure 10
If the crimping chamber DOES conform to the gage inspection, the dies may be considered dimensionally
correct and should be lubricated with a THIN coat of any good SAE 20 motor oil.
If the crimping chamber DOES NOT conform to the gage inspection, refer to Section 7 for information on
obtaining further evaluation and repair.
NOTE: For additional information regarding the use of a plug gage, reference Instruction Sheet 408-7424.
Rev C
Figure 11
408-1602
11 of 11
4
3
7. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 12. A complete inventory should be stocked and controlled to
prevent lost time when replacement of parts is necessary. Parts other than those listed should be replaced by
TE to insure quality and reliability. Order replacement parts through your TE representative, or call 1-800-5265142, or send a FAX of your Purchase Order to 717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Figure 12
8. REVISION SUMMARY
Changed callouts 3 and 4 in Figure 12
Rev C
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