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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
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.
© 2016 TE Connectivity Ltd. family of companies.
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.
Crimping Die Assemblies 46754-2,
46755-2, 46756-2, 46757-2, 46758-2,
46759-2, 46760-2, 59870-1, and 69653
CMA
WIRE SIZE
(Circular Mil Area)
(MCM)
(1)
Range
350
325,000-375,000
350 HD
400
375,000-450,000
500
450,000-550,000
500
600
550,000-650,000
600 HD
700
650,000-750,000
800
750,000-850,000
900
850,000-950,000
1000
950,000-1,125,000
1
MCM equals thousand circular mils
2
After crimping, product insulation will be embossed with 600
Figure 1
for the power units.
PRODUCT INFORMATION 1-800-522-6752
Die Assembly PN
Single Crimp
Dual Crimp
69653
---
46754-2
---
46755-2
---
---
46756-2
(2)
46756-2
---
59870-1
---
46757-2
---
46758-2
---
46759-2
---
46760-2
408-2456
for the crimping head and
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Instruction Sheet
408-1602
Rev C
10 NOV 16
1 of 11
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Summary of Contents for TE Connectivity 46754-2
- Page 1 1 of 11 All Rights Reserved. For latest revision and Regional Customer Service, visit our website at www.te.com. *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.
- Page 2 408-1602 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.
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Page 3: Crimping Procedure
408-1602 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. -
Page 4: Crimp Inspection
408-1602 4.2. Using Single-Crimp Die Assembly 1. Center the terminal or splice in the stationary die as shown in Figure 4. Figure 4 2. Activate the power unit so the moving die advances and holds the terminal or splice in place; but without deforming the wire barrel. - Page 5 408-1602 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...
- Page 6 408-1602 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).
- Page 7 408-1602 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.
- Page 8 408-1602 Dual-Crimp Die Assembly Figure 8 8 of 11 Rev C...
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Page 9: Maintenance And Inspection
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. - Page 10 408-1602 Figure 10 Gage Element Diameter Gage Element Diameter Die Assembly Die Assembly NO-GO NO-GO 13.564-13.571 13.815-13.818 20.422-20.429 20.673-20.676 46754-2 46759-2 [.5340-.5343] [.5439-.5440] [.8040-.8043] [.8139-.8140] 15.037-15.044 15.288-15.291 21.539-21.547 21.791-21.793 46755-2 46760-2 [.5920-.5923] [.6019-.6020] [.8480-.8483] [.8579-.8580] 16.612-16.619 16.863-16.866 18.288-18.296 18.539-18.542 46756-2 59870-1 [.6540-.6543]...
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Page 11: Replacement And Repair
408-1602 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 1-800-526- 5142, or send a FAX of your Purchase Order to 717-986-7605, or write to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION...