408-2292-3 Datasheet, PDF (2/6 Pages) TE Connectivity Ltd – Terminal Crimping Dies

WIRE
SIZE
1/0
2/0
250 MCM
350 MCM
400 MCM (2 Crimps)
500 MCM (2 Crimps)
600 MCM (2 Crimps)
777 MCM (2 Crimps)
DIE SET
NUMBER
68200-1
68201-1
68203-1
68204-1
68332-1
68206-1
46757-3
46758-2, 46758-3
CRIMPING HEAD
NUMBER
69099
69099
69099
68082
68082
68082
68082
68082
Figure 2
2.3. Wire Stripping and Crimping Procedures
A
DANGER
1/0
! Avoid personal injury. When operating power unit,
exercise caution while holding terminals or wire near
crimping area.
A. Wire Stripping Procedure
1. Select the proper size terminals and die set for
the wire size being used. See Figure 2.
2. Strip the wire to the dimensions indicated in
Figure 2.
CAUTION
! ^{Do NOT nick or cut conductor strands.}
B. Crimping Procedures (Single Crimp) 1/0 Through 350
MCM Terminals (Figure 3)
1. Ensure the wire size stamped on the terminal
corresponds with the wire size stamped on the dies.
2. Orient the 1/0 terminal with the dies so the large
slot in the terminal is rotated 30° to 60° from the
vertical as shown in Figure 3A. Orient the 250 MCM
and 350 MCM terminals with the dies so that the
large slot in the terminals is rotated 45° from the
vertical as shown in Figure 3A.
3. Position the terminals so the dies are centered on
the wire barrels of the terminals as shown in
Figure 3A.
4. Activate the power unit so the moving die
advances and holds the terminal in place. Do NOT
deform the terminal.
5. Insert a stripped wire all the way into the terminal
wire barrel. Activate the power unit to complete the
crimp.
6. Refer to Section 3 and Figure 5 for crimp
inspection.
C. Crimping Procedures (Dual Crimp) 400 MCM
Terminals (Figure 3)
1. Ensure the wire size stamped on the terminal
corresponds with the wire size stamped on the dies.
B
400 MCM
Rev B
408-2292-3
WIRE STRIP LENGTH
MINIMUM
MAXIMUM
23.82 [.938]
25.4 [1.000]
23.82 [.938]
25.4 [1.000]
39.67 [1.562]
41.28 [1.625]
39.67 [1.562]
41.28 [1.625]
44.45 [1.750]
46.02 [1.812]
44.45 [1.750]
46.02 [1.812]
50.8 [2.000]
52.37 [2.062]
50.8 [2.000]
52.37 [2.062]
Figure 3
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