TE Connectivity AMPOWER 68361-1 Bedienungsanleitung

Instruction Sheet

1 of 10

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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.

408-2710

18 NOV 2022 Rev H

1. INTRODUCTION

AMPOWER Crimping Die Assemblies 68361-1, 68253-1, 68304-1, and 59867-1 (shown in Figure 1) are

designed for use in DYNA-CRIMP™Crimping Head 69099, which is hydraulically activated by Hydraulic Power

Unit 69120-[ ] or Hydraulic Hand Pump 314979-1.

Figure 1: AMPOWER Crimping Die Assemblies 68361-1, 68253-1, 68304-1, and 59867-1

Lock screw

Stationary die

Ram lock screw

Locator assembly

DYNA-CRIMP crimping head 69099

Moving die

Flat on shank

AMPOWER™Crimping Die Assemblies

68361-1, 68253-1, 68304-1, and 59867-1

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Table 1 lists the dimensions for each die set. The weight is approximately 794 g [1 lb 12 oz].

NOTE

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

drawn to scale.

Figure 2: Dimensions

Length

Width

Height

Table 1: Dimensions by die set

Dimension

Die set

68253-1

68304-1

68361-1

59867-1

Length

61.98 [2.440]

71.50 [2.815]

61.98 [2.440]

Width

41.28 [1.625]

Height

73.76 [2.904]

Each die assembly, when installed in the crimping head, crimps AMPOWER Quick-Disconnect Terminals onto

standard wire sizes as listed in Table 3.

These instructions provide specific information regarding the die assemblies and applicable terminals. For

information regarding die insertion/removal and general operation, refer to the appropriate series 408

instruction sheet or series 409 customer manual listed in Table 2.

Table 2: Documentation

Product

Document

DYNA-CRIMP Crimping Head

408-2458

Hydraulic Power Unit

409-1950

Hydraulic Hand Pump

409-5860

Read these instructions thoroughly before crimping terminals.

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2. DESCRIPTION

Each die assembly features a stationary die, a moving die, and a locator assembly (see Figure 1). Both the

stationary and moving die have a shank (with a flat), which aligns and secures each die in the crimping head.

The locator assembly helps position the terminal in the stationary die.

3. INSTALLING AND REMOVING THE DIES

For installation and removal procedures, refer to instruction sheet 408-2458.

4. CRIMPING

DANGER

Moving parts can crush and cut. To avoid injury while operating the power unit, exercise caution when holding terminals or

wires near the crimping area.

1. Select a wire of the correct size and insulation diameter for the terminal (see Table 3). Verify that the

same wire size is stamped on the terminal and the dies.

2. Strip the wire to the length listed in Table 3. Do not nick or cut wire strands. See Figure 3.

Table 3: Crimping specifications

Wire size

Terminal

part number

Die set

part number

Strip length

Minimum

mm [in.]

Maximum

mm [in.]

1/0

52594-1

52594-2

52594-3

68361-1

29.46 [1.16]

30.99 [1.22]

2/0

52595-1

52595-3

68253-1

3/0

52596-1

59867-1

4/0

53631-1

68304-1

Figure 3: Stripping the wire

Terminal

Wire strip length

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3. Insert the terminal into the stationary die. Orient it so that the large, flat surface of the terminal is

parallel to, and rests against, the angular surface of the locator (Figure 4).

Figure 4: Positioning the terminal

Flat surface of terminal rests against locator

Quick-disconnect pins must be on this side of locator

Moving die

4. While holding the terminal in position, activate the power unit so that the moving die advances just

enough to hold the terminal in place. Do not deform the terminal wire barrel.

5. Insert the stripped wire all the way into the terminal wire barrel.

6. While holding the wire in place, activate the power unit through a complete cycle.

7. Allow the dies to open fully.

8. Remove the crimped terminal.

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5. INSPECTING THE CRIMP

Inspect crimped terminals by comparing to the ones shown in Figure 5 and Figure 6. Use only the terminals

that display the features of an acceptable crimp (Figure 5).

Figure 5: Features of an acceptable crimp

Embossed wire size matches size stamped on terminal and CMA of wire.

Crimp is located on wire barrel as shown (Table 4).

Insulation enters insulation barrel.

Distance from edge of terminal feature to center of crimp (Table 4).

Vertical centerline of crimp.

Large slot (45° off vertical centerline)

Table 4: Location of crimp on wire barrel

Die set

Size

Distance from edge of terminal

feature to center of crimp mm [in.]

Minimum

Maximum

68361-1

1/0

26.16 [1.03]

27.69 [1.09]

68253-1

2/0

59867-1

3/0

68304-1

4/0

30.99 [1.22]

32.51 [1.28]

408-2710

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Figure 6 shows problems that mean a crimp should be rejected. Most of these are the caused by a terminal

that is not properly aligned with the dies. Avoid unacceptable crimps by carefully following the procedures in

section 4 and performing regular tool maintenance (section 6).

As shown in Figure 6, the large slot in the terminal must meet the following requirements:

The height of the slot must be 6.35 to 6.48 mm [.250 to .255 in.].

At least 2.00 mm [.079 in.] of slot flat must exist.

If the slot is spread open too far, you can correct this by squeezing it in a vise.

Figure 6: Reasons to reject a crimp

Excessive flash. Damaged dies or wrong wire, terminal, or tooling combination was used.

Embossed wire size does not match size stamped on terminal or CMA of wire.

Strands are nicked or missing.

Large slot is deformed (spread open).

Incorrect crimp orientation.

Crimped too far off center, causing large slot to spread open.

Wire was not inserted far enough into terminal. Wire insulation did not enter insulation barrel.

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6. MAINTENANCE AND INSPECTION

The dies are inspected before being shipped. Inspect them immediately when they arrive at your facility to

determine whether any damage occurred during shipment.

6.1. Daily maintenance

Make each operator of the power unit aware of, and responsible for, the following daily maintenance

requirements:

Remove dust, moisture, and other contaminants with a clean, soft brush or soft, lint-free cloth. Do not

use objects that could damage the dies.

Protect all surfaces with a thin coat of any good SAE 20 motor oil. Do not oil excessively.

When the dies are not in use, store them in a clean, dry area.

6.2. Lubrication

To protect dies from rust when storing, lubricate all surfaces with SAE 20 motor oil as indicated in Table 5.

Table 5: Lubrication schedule

How tool is used

When to lubricate

In daily production

Daily

Daily (occasional)

Weekly

Monthly

Before using the dies, wipe off excess oil, particularly from the crimping area. Oil transferred from the crimping

area onto terminations can affect the electrical characteristics of the termination.

6.3. Periodic inspection

Regular inspections should be performed by quality control personnel. A record of scheduled inspections

should remain with the dies or be supplied to personnel responsible for the dies. Recommendations call for at

least one inspection per month. Base your inspection frequency on the amount of use, ambient working

conditions, operator training and skill, and established company standards. Perform the inspection as follows:

1. Remove accumulated dirt, grease, and foreign matter by immersing the dies in a suitable commercial

degreaser that does not affect paint or plastic material.

2. Inspect the crimp area for flattened, chipped, cracked, worn, or broken areas.

3. If damage or abnormal wear is evident, replace the dies. Refer to section 7, REPLACEMENT AND

REPAIR.

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6.4. Gaging the crimping die closure

This procedure requires the use of a plug gage (Figure 7) conforming to the dimensions listed in Table 6. TE

Connectivity does not manufacture or market these gages. For information regarding the use of a plug gage,

refer to instruction sheet 408-7424.

Figure 7: Recommended plug gage design

GO diameter

NO GO diameter

Wire barrel crimping chamber

GO element

NO GO element

Table 6: Gage diameters

Crimping die

part number

GO diameter

NO GO diameter

68361-1

7.544 - 7.551 [.2970 - .2973]

7.795 - 7.798 [.3069 - .3070]

68253-1

8.509 - 8.517 [.3350 - .3353]

8.760 - 8.763 [.3449 - .3450]

59867-1

9.576 - 9.583 [.3770 - .3773]

9.827 - 9.830 [.3869 - .3870]

68304-1

10.490 - 10.498 [.4130 - .4133]

10.742 - 10.744 [.4229 - .4230]

408-2710

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To gage the die closure, complete the following steps.

1. Remove the dies from the crimping head.

2. Remove traces of oil or dirt from the crimping chambers and plug gage.

3. Position the dies at the gaging height shown in Figure 8.

Figure 8: Gaging height

4. Align the GO element with the wire barrel crimping chamber. Gently push the element straight into the

crimping chamber. The GO element must pass completely through the crimping chamber.

5. Gage the wire barrel crimping chamber with the NO-GO element in the same manner as step 4. The

NO-GO element can start entry, but must not pass completely through the crimping chamber.

If the dies conform to the gage inspection, the crimping chamber is considered dimensionally correct.

If correct, lubricate the dies with a thin coat of any good SAE 20 motor oil and return them to service.

If not correct, return the dies to TE for further evaluation and repair. Refer to section 7,

REPLACEMENT AND REPAIR.

408-2710

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7. REPLACEMENT AND REPAIR

Due to the precision design, it is important that no parts of these dies be interchanged except those

replacement parts listed in Table 7. Any other parts should be replaced only by TE to ensure quality and

reliability of the tool. Order replacement parts through your TE representative. You can also order parts by any

of the following methods:

Go to TE.com and click the Shop TE link at the top of the page.

Call 800-522-6752.

Write to:

CUSTOMER SERVICE (038-035)

TE CONNECTIVITY CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

For customer repair services, call 800-522-6752.

Figure 9: Replacement parts

Table 7: Die set and component part numbers

Item

Part number

Description

Quantity per

assembly

Die set

68253-1

Die set

68304-1

Die set

68361-1

Die set

59867-1

308265-1

308265-2

308265-3

308265-4

Stationary die

308264-1

308264-2

308264-3

308264-4

Moving die

2-21000-7

Socket head cap screw 8-32 x .500 L

308266-1

Cover stop

311476-1

Locator stop

8. REVISION SUMMARY

Since the last revision of this document, the following changes were made:

Corrected errors in Table 3

Reformatted and edited

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