AMPOWER* Crimping Die Assemblies
68361-1, 68253-1, 68304-1, and 59867-1
DYNA-CRIMP*
Crimping Head 69099
Flat on
Shank
Stationary
Die
Locator
Assembly
Instruction Sheet
408-2710
18 Mar 11 Rev G
2. DESCRIPTION
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) which is used to align and secure each die in the
crimping head. The locator assembly is used to aid in
positioning the terminal in the stationary die.
Lockscrew
3. CRIMPING PROCEDURE
Install the dies according to the instructions contained
in 408-2458. Refer to the table in Figure 2 and select
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:
DANGER
To avoid personal injury when operating power unit,
exercise caution when holding terminals or wires
STOP
near crimping area.
Ram Lockscrew
Figure 1
Moving Die
1. Position terminal in stationary die so that large,
flat surface of terminal is parallel to and resting
against angular surface of locator.
2. Hold the terminal in position and activate power
unit so that moving die advances just enough to
hold terminal in place. Do not deform terminal wire
barrel.
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. 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
regarding the die assemblies and applicable terminals.
For information regarding die insertion/removal and
general operation of the DYNA-CRIMP Crimping
Head, refer to instruction sheet 408-2458. For
information on the Hydraulic Power Unit, refer to
customer manual 409-1950 and for information on the
Hydraulic Hand Pump, refer to 409-5860.
Reasons for reissue are provided in Section 6,
REVISION SUMMARY.
NOTE
Terminal
Wire Strip
Length
WIRE
SIZE
1/0
2/0
3/0
4/0
29.46
[1.16]
30.99
[1.22]
STRIP LENGTH
MIN.
MAX.
TERMINAL
NUMBER
52594-1, 52594-3,
and 52594-3
52595-1
52596-1
53631-1
Figure 2
DIE
SET
NUMBER
68361-1
68253-1
59867-1
68304-1
i
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
©2011 Tyco Electronics Corporation, Berwyn, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
All Rights Reserved
PRODUCT INFORMATION 1-800-522-6752
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
1
of 5
LOC B
408-2710
4.1. Daily Maintenance
Flat Surface of
Terminal Rests
Against Locator
1. Remove dust, moisture, and other contaminants
with a clean brush, or a soft, lint-free cloth. Do NOT
use objects that could damage the dies.
2. All surfaces should be protected with a thin coat
of any good SAE 20 motor oil. Do not oil
excessively.
3. When the dies are not in use, store them in a
clean, dry area.
Quick-Disconnect
Guide Pins Must
Be on this Side of
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
terminations may affect the electrical characteristics of
the termination.
Moving Die
Figure 3
4.3. Periodic Inspection
1. Remove accumulated dirt, grease, and foreign
matter by immersing the dies in a suitable
commercial degreaser that will not affect paint or
plastic material.
2. Inspect die crimp area for worn, cracked, or
broken surfaces. If damage is evident, return the
dies to TE for evaluation and repair. See Section 5,
REPLACEMENT AND REPAIR.
3. Insert stripped wire all the way into terminal wire
barrel.
4. Hold the wire in place and activate power unit
through a complete cycle.
5. Allow the dies to open fully, then remove the
crimped terminal.
Inspect crimped terminals by comparing them to the
ones shown in Figure 4. Use only the terminals that
meet the conditions shown in the "ACCEPT" column.
"REJECT" terminals can be avoided by carefully
following the above procedures and by performing
regular tool maintenance, as provided in Section 4,
MAINTENANCE AND INSPECTION PROCEDURE.
4.4. Crimping Die Closure Inspection
This inspection requires the use of a plug gage
conforming to the dimensions shown in Figure 5.
TE does not manufacture or market this gage.
To gage die closure, refer to Figure 6 and proceed as
follows:
1. Remove dies from crimping head.
2. Remove traces of oil or dirt from the crimping
chambers and plug gage.
3. Assemble and adjust dies to meet the "gage
dimension" indicated in Figure 6.
4. Align the GO element with the wire barrel
crimping chamber. Push element straight into the
crimping chamber without using force. The GO
element must pass completely through the crimping
chamber.
5. Check the wire barrel crimping chamber with the
NO-GO element in the same manner as step 4. The
NO-GO element may start entry, but must not pass
completely through the crimping chamber.
4. MAINTENANCE AND INSPECTION PROCEDURE
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations. Frequency of
inspection depends on:
•
The care, amount of use, and handling of the dies.
•
The presence of abnormal amounts of dust and
dirt in your facility.
•
The degree of operator skill.
•
Your own established standards.
The dies are inspected before being shipped;
however, it is recommended that the dies be inspected
immediately upon their arrival at your facility to ensure
that there was no damage during shipment. Due to the
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
408-2710
ACCEPT
REJECT
4
2
1
3
2
5
Slot Spread Open
Dimension “A”
Vertical
Centerline
45°
Large Slot
2.00 [.079] Min.
1
3
4
Vertical Centerline
6.35 / 6.48
[.250 / .255]
Slot Spreads Open
Slots that are open too
far may be closed by
squeezing in vise.
6
Wrong Crimp
Orientation
1
2
Crimp located on wire barrel as shown.
Embossed wire size matches CMA of wire being used
and wire size stamped on terminal.
Insulation enters insulation barrel.
Large slot 45° off vertical centerline of crimp.
1
Crimped too far off center causing large slot
to spread open.
Embossed wire size does not match CMA of wire
being used, or wire size stamped on terminal.
Wire not inserted far enough into terminal. Wire
insulation did not enter insulation barrel.
Excessive “flash” indicates wrong wire, terminal, or
tooling combination used, or damaged dies were used.
Nicked or missing strands.
Terminal was not oriented properly with dies
(see Figure 3). Depending on orientation, slot
will spread open.
2
3
3
4
4
5
DIE SET
68361-1
68253-1
59867-1
68304-1
SIZE
1/0
2/0
3/0
4/0
DIMENSION “A”
26.16 / 27.69 [1.03 / 1.09]
26.16 / 27.69 [1.03 / 1.09]
26.16 / 27.69 [1.03 / 1.09]
30.99 / 32.51 [1.22 / 1.28]
Figure 4
6
If dies conform to the gage inspection, the crimping
chamber is considered dimensionally correct. If
correct, the dies should be lubricated with a thin coat
of any good SAE 20 motor oil and returned to service.
If not correct, the dies must be returned for further
evaluation and repair. Refer to Section 5,
REPLACEMENT AND REPAIR.
Rev
G
3
of 5
408-2710
Suggested Plug Gage Design
GO Dia.
NO-GO Dia.
Dies Positioned At
“Gage Dimension”
Wire Barrel
Crimping Chamber
Gage Dim.
42.27 [1.664]
GO Element
CRIMPING
DIE NUMBER
68361-1
68253-1
59867-1
68304-1
NO-GO Element
GAGE DIMENSION
Figure 6
GO (DIA)
7.544 - 7.551
[.2970 - .2973]
8.509 - 8.517
[.3350 - .3353]
9.576 - 9.583
[.3770 - .3773]
10.490 - 10.498
[.4130 - .4133]
Figure 5
NO-GO (DIA)
7.795 - 7.798
[.3069 - .3070]
8.760 - 8.763
[.3449 - .3450]
9.827 - 9.830
[.3869 - .3870]
10.742 - 10.744
[.4229 - .4230]
6. REVISION SUMMARY
Since the last revision of this document, the following
changes were made:
•
Updated document to corporate requirements.
5. REPLACEMENT AND REPAIR
Replacement parts are listed in Figure 7. Parts other
than those listed in Figure 7 should be replaced by TE
to ensure quality and reliability of the tool. Order
replacement parts through your TE representative, or
call 1-800-526-5142, or send a facsimile of your
purchase order to 1-717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For additional information regarding the use of a plug
gage, refer to instruction sheet 408-7424.
For customer repair service, contact a TE
representative at 1-800-526-5136.
Rev
G
4
of 5
408-2710
Dim. “A”
Dim. “C”
1
5
Dim. “B”
3
2
4
Weight Approximately
794 g [1 lb 12 oz]
ITEM
NUMBER
1
2
3
4
5
DIE SET NUMBERS AND COMPONENT PART NUMBERS
68253-1
2-21000-7
308266-1
311476-1
308264-1
308265-1
61.98
[2.440]
73.76
[2.904]
41.28
[1.625]
68304-1
2-21000-7
308266-1
311476-1
308264-2
308265-2
71.50
[2.815]
73.76
[2.904]
41.28
[1.625]
68361-1
2-21000-7
308266-1
311476-1
308264-3
308265-3
61.98
[2.440]
73.76
[2.904]
41.28
[1.625]
59867-1
2-21000-7
308266-1
311476-1
308264-4
308265-4
61.98
[2.440]
73.76
[2.904]
41.28
[1.625]
Figure 7
PART DESCRIPTION
SCREW, Skt Hd Cap, 8-32 x .500 L
STOP, Cover
STOP, Locator
DIE, Moving
DIE, Stationary
QTY PER
ASSY
2
1
1
1
1
Dim. “A”
Dim. “B”
Dim. “C”
Rev
G
5
of 5
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