TE Connectivity AMPOWER 68361-1 Instruction Sheet

Lockscrew
Ram Lockscrew
Figure 1
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.
Dimensions in this instruction sheet are in metric
NOTE
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
i
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All Rights Reserved
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
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
Moving Die
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
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.
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:
To avoid personal injury when operating power unit,
DANGER
exercise caution when holding terminals or wires
near crimping area.
STOP
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.
Terminal
WIRE
STRIP LENGTH
SIZE
MIN. MAX.
1/0
29.46 30.99
2/0
[1.16] [1.22]
3/0
4/0
Figure 2
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Instruction Sheet
408-2710
18 Mar 11 Rev G

Wire Strip
Length
DIE
TERMINAL
SET
NUMBER
NUMBER
52594-1, 52594-3,
68361-1
and 52594-3
52595-1 68253-1
52596-1 59867-1
53631-1 68304-1
1 of 5
LOC B