Instruction Sheet
Power Series 50
Connector Assembly Kits 408--8636
LOC B
1of 3
E2010 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
02 FEB 10 Rev A647891- [ ], 647892- [ ], and 647893- [ ]
Housing
C
l
o
s
ed
B
a
r
r
e
l
Co
n
t
a
ct Reduc
i
n
g
B
u
s
h
i
n
g
(Available Separately
for Contact Size 6)
Key
(Position Varies)
Contact Cavities
Marking for
Positive Polarity
Marking for
Negative Polarity
CONNECTOR
C
O
N
A
C
REDUCING BUSHING
C
O
N
N
E
C
O
R
ASSEMBLY
KIT
CONTACT
SIZE Part Number Reduces to
Wire Size (AWG)
647891--[ ] 8 — —
647840--1 12--10
647892--[ ] 6 1445762--1 8
[
]
1445763--1 16--14
647893--[ ] 10--12 — —
Figure 1
1. INTRODUCTION
These instructions cover assembly and disassembly
of Power Series 50 Connector Assembly Kits
647891--[ ], 647892--[ ], and 647893--[ ].
For detailed application requirements, refer to
Application Specification 114--13071.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are
not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
Each kit consists of a hermaphroditic housing and two
closed barrel contacts. The contacts accept stranded
(minimum of 19 strands recommended) copper wire
with a maximum insulation diameter of 11.18 [.44].
Wire size (AWG) corresponds to the contact size.
A reducing bushing is available for contact size 6 to
accommodate smaller wire sizes to a minimum of size
16 AWG. See Figure 1.
The housing features two contact cavities each
marked on top of the housing with a plus (+) to
indicate positive polarity and a minus (--) to indicate
negative polarity. Each housing is color coded to
provide visual reference for proper mating and a
molded--in mechanical key at the mating face
prevents inadvertent mating of different colored
housings (housings with same position keys will only
engage housings of the same color).
Refer to the specific customer drawing for
available colors.
3. ASSEMBLY PROCEDURE
These Kits Must Be Assembled by A Qualified Electrician in
Accordance with National and Local Electrical Codes and
the Following Instructions.
To avoid risk of electric shock in applications
where the connectors are used external to a
device or as the primary means of disconnecting
power supplies or charging equipment, care must
be taken to avoid touching exposed contacts.
1. Cut the wire to length.
2. Using Cable Stripper/Slitter Tool 606700--1, strip
the wire to the dimension given in Figure 2. Be
careful not to nick or scrape any part of the wire.
3. Thoroughly clean tarnished copper wire using a
stiff wire brush, or other suitable method, that
penetrates the entire bundle and cleans every
conductor. Restore the wire to a bright copper
finish.
Figure 2
12.06--13.33 [.475--.525]
Recommended Strip Length
Note: Not to Scale Conductors
Insulation
NOTE
i
NOTE
i
NOTE
i
DANGER
408- 8636
Power Series 50 Connector Assembly Kits 647891- [ ], 647892- [ ], and 647893- [ ]
Rev A2 of 3 Tyco Electronics Corporation
The contact wire barrel is lined with silver plating
to assure consistently high conductivity which will
be reduced if tarnished wire is used.
4. If used, slide the reducing bushing onto the wire
conductors to the dimension given in Figure 3.
Make sure that the wire insulation DOES NOT
enter the reducing bushing and the ends of the
conductors are visible.
Figure 3
Note: Not to Scale
1.52 [.060] Max
Reducing Bushing (If Used)
Wire Insulation
5. Insert the wire conductors into the contact wire
barrel until it stops. If used, the reducing bushing
must be flush with the contact wire barrel or can
protrude from the wire barrel no more than the
dimension given in Figure 4. DO NOT allow the
insulation to enter the wire barrel.
Figure 4
0.38 [.015] Max
Reducing Bushing (If Used)
Contact Wire Barrel Note: Not to Scale
6. Using any of the hand tools given in Figure 5,
crimp the contact according to the instructions
packaged with the tooling.
7. Inspect the crimp according to the following:
1wire insulation is not cut or broken
2reducing bushing (if used) is flush with, or
protrudes slightly from, wire barrel
3wire insulation does not enter wire barrel
4contact is straight and not damaged in
any way
5there are no loose conductors or conductors
folded over wire insulation
6conductors are visible between reducing
bushing (if used) or wire barrel and wire
insulation
7crimped area is symmetrical on both sides
of wire barrel
Note: Dual--Indent Crimp Shown
Same Criteria Applies to Single--Indent Crimp
1
2
3
4
5
6
7
TYCO ELECTRONICS (Single--Indent Crimp) PICO CORPORATIONHPNEUMATIC HAND TOOL (Dual--Indent Crimp)
CRIMP TOOL 1526955--1
(
4
0
8
8
5
4
0
)
AMERICAN ELECTRICAL
TERMINAL
(
AET
)
SERIES DIE SET LOCATOR
DIE CLOSURE
FOR CONTACT SIZE
(408--8540)
E
R
M
I
N
A
(
A
E
)
HAND TOOL T--406
S
E
R
I
E
S
D
I
E
S
E
O
C
A
O
R
6and8 10--12
4
0
0
414DA--4583
4
5
8
2
1
A
da
p
ter 1527508--1
A
d
a
p
t
e
r
5
9
9
2
400 414DA--4582 4582--1
1
5
2
i
n
1
3
4
i
n
A
d
a
p
t
e
r
1
5
2
7
5
0
8
-
-
1
(Marking A)
A
dapter 5992
5
0
0
514DA--7033
7
0
3
3
1
.152 in. .134 in.
500 514DA--7034 7033--1
Figure 5
HTooling available from Pacific Industrial Components (PICO) Corporation at http://www.picotools.com
NOTE
i
408- 8636
Power Series 50 Connector Assembly Kits 647891- [ ], 647892- [ ], and 647893- [ ]
3of 3Rev ATyco Electronics Corporation
8. Refer to Figure 6, and install each contact into
the housing as follows:
To avoid risk of electric shock, DISCONNECT the
electrical supply and DE--ENERGIZE the
connectors (this might include disconnecting the
cable from the battery) before installing the
contacts into the housing.
a. From the wire side of the housing, align the
contact with the appropriate contact cavity
making sure that the underside of the contact
faces the housing retention spring.
b. Insert the contact straight into the contact
cavity until an audible “click” is heard. Slightly
pull back on the wire to make sure that the
contact is fully latched onto the retention spring.
DO NOT force the contacts into the housing.
Figure 6
Retention
Spring
Wire Side
of Housing
Underside
of Contact
4. MATING (Figure 7)
To avoid risk of electric shock, DISCONNECT the
electrical supply and DE--ENERGIZE the
connectors (this might include disconnecting the
cable from the battery) before mating or unmating
the connectors.
Align the mating faces of the housings, and push the
housings together. DO NOT force the housings to
mate. When fully mated, the housings must appear
flush at the point of engagement.
Figure 7
Point of
Engagement
5. DISASSEMBLY
To avoid risk of electric shock, DISCONNECT the
electrical supply and DE--ENERGIZE the
connectors (this might include disconnecting the
cable from the battery) before removing the
contacts into the housing.
1. Pull the housings straight apart (DO NOT force
them to unmate).
2. Using Extraction Tool 68265--1 (or a standard
insulated screwdriver with 1/4--in. flat blade),
remove each contact from the housing as follows:
a. At the mating face of the housing, insert the
tip of the tool between either side of the contact
and the contact cavity.
b. Push the handle of the tool toward the bottom
(flat side) of the housing so that the housing
retention spring is depressed away from the
underside of the contact. While holding the tool
in position, push the wire in the same direction,
and gently pull back until the contact is free from
the housing.
6. REPLACEMENT AND REPAIR
The contact, housing, and reducing busing are not
repairable. DO NOT use damaged or defective
contacts, housings, or reducing bushings. DO NOT
re--use terminated contacts or reducing bushings by
removing the wire.
7. REVISION SUMMARY
Revisions to this instruction sheet include:
SUpdated instruction sheet to corporate
requirements
SChanged die set part numbers for pneumatic
tool in Figure 5
DANGER
CAUTION
!
DANGER
DANGER