68204-1 Tyco Electronics, 68204-1 Datasheet - Page 3

• Manufacturer Part Number: 68204-1
• Description: TOOL DIE AMPOWER DUAL 350MCM
• Manufacturer: Tyco Electronics

Specifications of 68204-1

• Lead Free Status / RoHS Status: Not applicable / Not applicable

C. Crimping Procedures (Dual Crimp) 400 MCM
Terminals
D. Crimping Procedures (Dual Crimp) 500 and 600 MCM
Terminals
Rev A
AMPOWER Disconnect Terminal Crimping Dies
CAUTION
1. Ensure the wire size stamped on the terminal
corresponds with the wire size stamped on the
dies.
2. Orient all terminals with the dies so the large
slot in the terminal is rotated 45 from the vertical
as shown in Figure 3B.
3. First Crimp – Position the terminal so the edge
of the stationary die is aligned with the outer crimp
location mark as shown in Figure 3B(a).
4. Activate the power unit so the moving die
advances and holds the terminal in place. Do NOT
deform the terminals.
5. Insert a stripped wire all the way into the
terminal wire barrel.
6. Activate the power unit to complete the first
crimp.
7. Second Crimp – Position the terminal so the
edge of the stationary die is aligned with the inner
crimp location mark as shown in Figure 3B(b).
8. Activate the power unit to complete the second
crimp.
9. Refer to Section 3 and Figure 5 fro crimp
inspection.
1. Ensure the wire size stamped on the terminal
corresponds with the wire size stamped on the
dies.
2. Orient the terminal with the dies so the large slot
in the terminal is rotated 45 from the vertical as
shown in Figure 4A.
3. First Crimp – Position the terminal so the dies
are centered between the crimp marks on the wire
barrel of the terminal as shown in Figure 4B(a).
4. Activate the power unit so the moving die
advances and holds the terminal in place. Do NOT
deform the terminal barrel.
5. Insert a stripped wire all the way into the
terminal barrel.
!
(Figure 3)
(Figure 4)
Do NOT allow the wire insulation to enter the
barrel of the terminal.
Tyco Electronics Corporation
3. CRIMP INSPECTION
Inspect crimped terminals by checking the features
described in Figure 5. Use only terminals meeting the
conditions shown in the “ACCEPT” column.
“REJECT” terminals can be avoided through careful
use of instructions in Section 2, and by performing
regular die maintenance as instructed in Section 4.
A
500-600 MCM
B
CAUTION
6. Activate the power unit to complete the first
crimp.
7. Remove the terminal from the die.
8. Before making the second crimp on the
terminal, it will be necessary to either:
9. Second Crimp – Position the terminal in the die
as shown in Figure 4B.
10. Activate the power unit to complete the second
crimp.
11. Refer to Section 3 and Figure 5 for crimp
inspection.
Large Slot in Terminal Must Be Rotated 45 From Vertical
S Turn the terminal around
S Turn the crimping head around
S Turn the die set around
!
(a) To make 1st crimp, center
crimp area of dies between
crimp marks of terminal
Vertical
Do NOT allow the wire insulation to enter the
barrel of the terminal.
1st Crimp
45
Figure 4
Crimping Head
Turned Around
Location
Crimp
Marks
Large Slot
(b) To make 2nd crimp, either:
Turn terminal around, turn crimping
head around, or turn die set around
2nd Crimp
408-2292-3
Crimp
Location
Marks
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