Instruction Sheet

408-8990
Aluminum ShearBolt Connector 05 JUL 06 Rev D

Shear Bolts (4)

Typical for Both Conductor Ends

Straight Conductor
Cut Insulation

Shear Bolts (6)

Strip

Connector Body Length

Insert
(Refer to Table)

NOTE: Not to Scale

CONNECTOR CABLE

REMOVE INSERTS
PART NUMBER OD SOCKET CONDUCTOR
LENGTH SIZE STRIP LENGTH FOR CONDUCTOR
AND in. SIZE OD RANGE
in. [mm] RANGE in. [mm] SIZES in. [mm]
CATALOG NUMBER [mm] in. [mm] in. [mm]
GREATER THAN:

2 AWG 4/0 AWG

1099739-1
3.9 1.22 11/16 Compact Stranded .268-.681 Standard Stranded
ASBS-2C-350 1.87 [47.6]
[100] [31] [17] to 350 kcmil [6.8-17.3] .528 [13.4]
(4-Bolt)
Standard Stranded Diameter

350 kcmil 600 kcmil

1099735-1
6 1.52 3/4 Compact Stranded .616-.998 Compact Stranded
ASBS-350C-750 2.87 [73]
[152] [39] [19] to 750 kcmil [15.6-25.3] .813 [20.6]
(6-Bolt)
Standard Stranded Diameter

600 kcmil 750 kcmil

1099848-1
8 1.75 7/8 Compact Stranded .813-1.152 Standard Stranded
ASBS-600C-1000 3.87 [98.4]
[203] [44.4] [22] to 1000 kcmil [20.6-29.2] .998 [25.3]
(6-Bolt)
Standard Stranded Diameter

Figure 1
1. INTRODUCTION NOTE ShearBolt Connectors are designed to be

compatible will all Raychem cable accessories

This instruction sheet provides installation procedures
for Aluminum ShearBolt Connectors ASBS–2C–350,
ASBS–350C–750, and ASBS–600C–1000 as shown
in Figure 1. The aluminum shearbolt connector can
be used for Al–Al (aluminum–aluminum) and Al–Cu
(aluminum–copper) applications.
and insulation products. For other applications,
please consult the manufacturer's installation
instructions for compatibility.
Reasons for reissue of this instruction sheet are
provided in Section 3, REVISION SUMMARY.

NOTE Dimensions in these instructions are in imperial

units [with metric units in brackets]. Figures are 2. INSTALLATION PROCEDURES

for reference only and are not drawn to scale.

2.1. Cable Preparation

To obtain information on energy products,
visit the Tyco Electronics Energy website at NOTE DO NOT use a conductor that has been

http://energy.tycoelectronics.com. previously terminated.

E 2006 Tyco Electronics Corporation, Harrisburg, PA ENERGY CUSTOMER CENTER 1-800-327-6996 This controlled document is subject to change. 1 of 2
All International Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service,

Tyco and Raychem are trademarks. *Trademark visit our website at www.tycoelectronics.com LOC B
Other products, logos, and company names used are the property of their respective owners.
 Aluminum ShearBolt Connector
1. Ensure that each conductor end has a straight
(right–angle) cut. Strip both conductor ends to the
dimensions shown in Figure 1.
For Raychem HVS product applications, the strip
NOTE
length must be reduced by .125 in. [3.1 mm] to
eliminate any gap between connector and
insulation.
2. Using a wire brush dedicated for use on
aluminum or copper conductors, thoroughly clean
the bare surface strands of each conductor, then:
— for aluminum conductors, immediately apply an
oxidation inhibiting compound to the conductors
to prevent reformation of insulation oxides
— for copper conductors, no oxidation inhibiting
compound is required
2.2. Connector Installation
1. Determine conductor sizes that have to be
connected. Remove or keep inserts according to
each application (see table in Figure 1 for details).
If insert removal is required, use a small
screwdriver to lift the insert from the connector
body.
DO NOT remove inhibitor contained inside the
NOTE
connector.
2. Back out all bolts to give clearance for the
conductor in the connector body. Insert the
conductors into the connector until the conductor
ends butt against the center stop of the connector.
Tightening Sequence
5 4
1
Head of Bolt
Sheared Off
(Ref)
3 6
Figure 2
2 of 2
408-8990
NOTE In case of two different conductor sizes, we
recommend to first insert the larger conductor
into the connector barrel.
NOTE In case of Raychem HVS product applications,
insert conductors so that insulation butts up
against the end of connector.
3. Bolts are tightened in a three–step process:
i) Hand–tighten the bolts to firmly grip
conductors in place. Follow the tightening
sequence shown in Figure 2. Use the same
sequence when installing a four–bolt connector.
ii) Using a wrench with a hexagonal socket,
tighten the bolts one to one and a half turns,
repeating the sequence in the previous step.
Bolts should remain unsheared. Prevent core
bending by using a holding tool (part number
188072–000 or equivalent) as shown in
Figure 2.
iii) Repeat the sequence (above), tightening
each bolt until the head of the bolt shears off.
4. Smooth sharp edges of protruding bolts (use a
file for deburring bolt edges).
3. REVISION SUMMARY
S Updated document to corporate requirements
S Changed dimension information in Figure 1
S Added new NOTES to Paragraphs 2.1.1 and
2.2.2
2
Holding Tool
(Part Number
188072-000)
Rev D