COMPRESSION DEAD-END &

JUMPER TERMINAL
FOR ACCC & ULS ACCC CONDUCTORS
INSTALLATION INSTRUCTIONS
IMPORTANT SAFETY INFORMATION
!

READ AND COMPLETELY UNDERSTAND ALL INSTRUCTIONS BEFORE INSTALLING PRODUCT. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH.

This product is intended for use by trained technicians only. This product should not be used by anyone who is not familiar with
and not trained to use it. When working in the area of energized lines, extra care should be taken to prevent accidental electrical
contact. Be sure to wear proper safety equipment per your company protocol. These instructions are not intended to supersede
any company construction or safety standards. These instructions are offered only to illustrate safe installation for the individual.
PLP products are intended for the specified application only. Do not modify this product under any circumstances. Do not reuse
or reinstall any PLP product unless that capability is expressly indicated in the product’s Installation Instructions. For proper
performance and personal safety, be sure to select the proper PLP product before installation. PLP products are precision devices.
To ensure proper performance, they should be stored in cartons under cover and handled carefully.

TABLE OF CONTENTS
Compression Dead-End.......................................................................................... 2
Jumper Terminal..................................................................................................... 8
Complete Dead-End Jumper Terminal Assembly...........................................11

INSTALLATION OVERVIEW

Second "Stop" Mark First

(May not be Present) "Stop" Mark

Second First
"Start" Mark "Start" Mark

"Stop" Mark
Jumper

NOTE: The product is imprinted with instructional words, such as "Start" and "Stop" to aid installation.

SP3457-6
 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

PRODUCT COMPATIBILITY
These Installation Instructions are valid for PLP ACCC and ULS ACCC Compression Dead-End Assemblies, Compression Jumper Terminal
Assemblies individually, or the Full Compression Dead-End with Jumper Terminal.

PRECAUTIONARY MEASURES
CAUTION
Failure to follow the precautions, notes, and steps contained within these Installation Instructions represents a misapplication of the
product. This product and application procedure are for ACCC & ULS ACCC conductors.

(1) Ensure that the correct compression product has been selected for the conductor. Compare catalog numbers of the product with
associated conductor size/range published in PLP literature.

(2) Be certain that the dies being used to compress the fittings match the engraved sizes marked on the product surfaces. The dies will
have markings on the surface of the die face or the edges of the die.

(3) The compression press and the dies MUST be inspected before use. Ensure that they are well lubricated; there are no hydraulic oil
leaks; the press is of the correct size (60- or 100-Ton) to adequately compress the fittings; die surfaces mate completely when the
press is fully extended; and that the dies are in good condition without significant damage or wear.

(4) Before installation, the mating surfaces of the products to be installed, such as the inner bore of the aluminum tube, the inner bore
and outer surfaces of steel hardware, must be inspected for surface imperfections, etc. If any significant irregularities exist, the
products MUST be discarded or returned to PLP. Do NOT install defective or damaged compression hardware.

PACKAGE COMPONENTS
COMPRESSION DEAD-END

2
4

2 1
3

5 6

1. Aluminum Alloy Dead-End Body Tools Required:

2. Galvanized Steel-Forged Dead-End Eye • 60- or 100-Ton Press • Conductor strippers
(or Steel Forged Clevis Head)
• Product-Specific Aluminum • Hacksaw with
3. Seal (AH) Dies fine-tooth blade
4. Inner Sleeve • Torque Wrench • Wire brush
5. Collet • Large Adjustable Wrench • Marker pen
6. Housing • File • Tape
7. (Not shown) Sand Paper • Measuring Tape/Caliper • Lubricant or
8. (Not shown) Inhibitor • Utility Knife bar soap

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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

ACCC & ULS ACCC CONDUCTOR INFORMATION

Small Sizes
USA "A" "B"
International Outside Diameter
ACCC Code kcmil mm2 Exposed Core Length Approximate Eye Distance
ACCC Code Name in (mm)
Name in (mm) in (mm)
156.5 Skadar 79.3 0.523 (13.2842) 9.05 (230) 1.97 (50)
221.8 Rijeka 112.4 0.535 (13.589) 9.05 (230) 1.97 (50)
242.2 Silvassa 122.7 0.565 (14.351) 9.05 (230) 1.97 (50)
Pasadena 297.2 Helsinki 150.6 0.616 (15.6464) 9.05 (230) 1.97 (50)
307.3 Jaipur 155.7 0.650 (16.51) 9.05 (230) 1.97 (50)
350.1 Zadar 177.4 0.673 (17.0942) 9.05 (230) 1.97 (50)
370.6 Rovinj 187.8 0.673 (17.0942) 9.05 (230) 1.97 (50)
Oceanside 383.2 194.2 0.680 (17.272) 9.05 (230) 1.97 (50)
Linnet 430.5 Copenhagen 219.9 0.720 (18.288) 9.05 (230) 1.97 (50)
Oriole 438.6 Reykjavik 223.1 0.741 (18.8214) 9.05 (230) 1.97 (50)
491.0 Gdansk 248.8 0.756 (19.2024) 9.05 (230) 1.97 (50)
Waco 454.0 Glasgow 236.7 0.770 (19.558) 9.05 (230) 1.97 (50)
Laredo 529.8 Casablanca 273.6 0.807 (20.4978) 9.05 (230) 1.97 (50)
Hawk 611.3 Lisbon 315.5 0.858 (21.7932) 9.05 (230) 1.97 (50)
Dove 713.5 Amsterdam 367.4 0.927 (23.5458) 9.05 (230) 1.97 (50)
788.2 Cordoba 399.4 0.961 (24.4094) 9.05 (230) 1.97 (50)
Amarillo 784.7 Leipzig 421.4 0.990 (25.146) 9.05 (230) 1.97 (50)
Grosbeak 821.4 Brussels 421.4 0.990 (25.146) 9.05 (230) 1.97 (50)
NOTE: ULS conductors with the same name will be built to the same process as the standard conductors above.

Medium Sizes
USA "A" "B"
International Outside Diameter
ACCC Code kcmil mm2 Exposed Core Length Approximate Eye Distance
ACCC Code Name in (mm)
Name in (mm) in (mm)
451.0 Monte Carlo 228.5 0.818 (20.777) 12.40 (315) 1.57 (40)
Irving 609.5 Oslo 313.8 0.882 (22.403) 12.40 (315) 1.57 (40)
Lubbock 903.9 Stockholm 453.7/463.3 1.040 (26.416) 12.40 (315) 1.57 (40)
Galveston 1011.3 Warsaw 507.5 1.090 (27.686) 12.40 (315) 1.57 (40)
Drake 1025.6 Dublin 524.5 1.108 (28.1432) 12.40 (315) 1.57 (40)
1072.6 Kolkata 543.5 1.127 (28.6258) 12.40 (315) 1.57 (40)
Curlew 1033.0 Mahakam 544.9 1.140 (28.956) 12.40 (315) 1.57 (40)
Plano 1059.5 Hamburg 546.5 1.127 (28.6258) 12.40 (315) 1.57 (40)
Corpus Christi 1103.0 Milan 567.7 1.146 (29.1084) 12.40 (315) 1.57 (40)
Arlington 1151.1 Rome 592.5 1.177 (29.8958) 12.40 (315) 1.57 (40)
Cardinal 1221.8 Vienna 629.2 1.198 (30.4292) 12.40 (315) 1.57 (40)
Fort Worth 1300.4 Budapest 668.3 1.240 (31.496) 12.40 (315) 1.57 (40)
1352.7 Mumbai 685.4 1.251 (31.7754) 12.40 (315) 1.57 (40)
El Paso 1349.9 Prague 690.7 1.251 (31.7754) 12.40 (315) 1.57 (40)
1386.0 Ratchaburi 702.4 1.257 (31.93) 12.40 (315) 1.57 (40)
Beaumont 1427.6 Dhaka 723.9 1.294 (32.8676) 12.40 (315) 1.57 (40)
1447.0 Munich 733.2 1.293 (32.8422) 12.40 (315) 1.57 (40)
San Antonio 1474.9 London 759.0 1.315 (33.401) 12.40 (315) 1.57 (40)
Bittern 1581.6 Paris 813.7 1.345 (34.163) 12.40 (315) 1.57 (40)
NOTE: ULS conductors with the same name will be built to the same process as the standard conductors above. 3
 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

ACCC & ULS ACCC CONDUCTOR INFORMATION CONTINUED

Large Sizes
USA "A" "B"
International Outside Diameter
ACCC Code kcmil mm2 Exposed Core Length Approximate Eye Distance
ACCC Code Name in (mm)
Name in (mm) in (mm)
Dallas 1794.9 Antwerp 944.9 1.452 (36.8808) 12.40 (315) 1.57 (40)
Houston 1927.4 Berlin 1006.6 1.504 (38.2016) 12.40 (315) 1.57 (40)
Lapwing 1948.9 Madrid 1013.1 1.506 (38.2524) 12.40 (315) 1.57 (40)
Falcon 2045.1 1036.3 1.545 (39.243) 12.40 (315) 1.57 (40)
Chuckar 2241.5 1135.8 1.604 (40.7416) 12.40 (315) 1.57 (40)
Bluebird 2740.6 Athens 1409.8 1.762 (44.7548) 12.40 (315) 1.57 (40)
NOTE: ULS conductors with the same name will be built to the same process as the standard conductors above.

DEAD-END ASSEMBLY APPLICATION

1 Starting from the end, measure and mark the

conductor according to the "Exposed Core Length"
column A in the provided table on page 3 and 4.

2 Apply tape approximately 1" (25 mm) back from the mark to secure the aluminum strands and maintain the conductor diameter
after the cut is made.

3 Cut the outer strands at the strand mark to expose

the composite core.
NOTE: Take care to not cut or damage the core.
Ensure that the core end is not crushed. Failure to
follow these instructions could result in a
poor connection. PLP recommends the use of a
conductor trimming tool for this step.

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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

4 Wipe the outer surface of the core clean and

free of oil with a cloth. Use the provided 220 grit
sandpaper to rub the core lightly to remove the
shine or gloss. Rewipe the core with a clean cloth.

5 Clean/wire-brush the entire aluminum area to be

covered by the compression hardware. Check that
no residue or surface particles remain.

6 Apply the supplied oxide inhibitor (grease) to

the aluminum strands to be covered by the
compression hardware.

NOTE: Only use the supplied oxide inhibitor. Use of

any unqualified product may affect function.

7 With the tapered end of the inner aluminum

sleeve facing the end of the conductor, slide it
approximately 3 ft (1 m) onto the conductor.

8 Apply the oxide inhibitor (grease) to the surface of

the inner aluminum sleeve, excluding the tapered
section.

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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

9 Slide the outer alumimum tube over the conductor toward the inner aluminum sleeve.

NOTE: Do not slide the outer aluminum tube past the inner aluminum sleeve.

10 Using a felt tip marker, make a mark on the core 3"

(76 mm) from the end of the aluminum strands.

11 Slide the collet housing, with the wrench flats

facing the conductor, onto the core. Then slide
the collet, with the narrow end facing the collet
housing, onto the core until the edge reaches the
3" (76 mm) mark. A minimum of 1/4" (6 mm) of
the core must be exposed through the back 1/4"
of the collet. (6 mm)

12 Ensure that the seal is present on the steel eye/

clevis. Then screw the steel eye/clevis into the
collet housing until hand-tight. Then, while holding
the collet housing steady, use a torque wrench to Seal
fully tighten to a minimum of 85 ft-lb (115 Nm).
Check the location of the collet and ensure
that approximately 3" (76 mm) of the core is Steel Eye/
exposed. Avoid skewing the conductor core to Clevis
prevent damage. Housing
NOTE: Do not torque housing. Hold housing with 3" (76 mm)
wrench while torquing the steel eye/clevis. Minimum

13 Slide the outer aluminum tube towards the eye,

lining up the edge of the pad with the mark on the
steel eye/clevis. If no mark is present, offset the
steel eye/clevis to the dimension in the table in
column B, "Approximate Eye Distance" on page 3.

NOTE: This distance can vary ± 0.20" (5 mm),

installer may adjust after first complete
compression assembly. Refer to Column B "Approximate Eye
Distance" on Page 3 Chart

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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

14 Position the inner aluminum sleeve so that 1" (25

mm) is sticking out of the outer aluminum tube.

15 Ensure that the compression die surfaces are

clean and free of burrs or debris. Either lubricate
the compression dies with a wet lubricant or rub
on a dry lubricant to the components compression
surface. After checking that the correct die size
is being used, begin compressing on the outer
aluminum tube at the opposite end of the eye/
clevis at the "Start" knurl.

CAUTION
Clean dies and sufficient but not excessive
lubrication are the most important factors in
applying proper compressions and avoiding
curvature.

16 Overlap compressions by 1/3 to 1/2 of their

lengths in the direction of the eye to ensure
compression. Continue until the compressions
meet the first stop mark on the outer tube.

! WARNING
If the seal is compressed at the end of the
first compression, the fitting must be removed
and a new fitting installed with 0.20" (5 mm)
added to the eye distance, for each incomplete
compression to the First "Stop" Mark.
Second
First First Second "Stop" Mark
"Start" Mark "Stop" Mark "Start" Mark (if present)

17 Start second compression at the second "Start"

knurl (as shown in Step 16) and compress towards
the steel eye/clevis. Continue compressions
towards the eye or clevis until seal is compressed
(if the second "Stop" mark is present, it is okay
to compress beyond it to seat the seal. Do not
over-compress the seal.
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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

PACKAGE COMPONENTS
JUMPER TERMINAL

1
2

1. Aluminum Alloy Jumper Terminal Tools Required:

2. Fastener Kit • 60- or 100-Ton Press • Wire brush
3. Inner Sleeve • Product-Specific Aluminum • Torque wrench
(AH) Dies
• Wrench or
• Filler Compound socket wrench
(Rated for Application)
• Caulking Gun
• File
• Measuring Tape
• Utility Knife

JUMPER TERMINAL APPLICATION

1 Clean/wire-brush the entire aluminum area to

be covered by the compression hardware per
your standard company practices. Ensure that no
residue or surface particles remain.

2 Apply the supplied oxide inhibitor (grease) to

the aluminum strands to be covered by the
compression hardware.

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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

3 Use the supplied 220 grit sandpaper to lightly sand

the outside of the inner aluminum sleeve.

4 With the tapered end of the inner aluminum sleeve

facing the conductor, slide it down until the non-
tapered end lines up with the end of the conductor.

5 Apply the supplied oxide inhibitor (grease) to the

outside of the inner aluminum sleeve, excluding
the tapered portion.

6 Slide the jumper terminal onto the inner aluminum

sleeve such that 1" (25 mm) of the inner aluminum
sleeve is sticking out.

7 Ensure that the compression die surfaces are clean and free of burrs or debris. Either lubricate the compression dies with a wet
lubricant or rub a dry lubricant onto the component's compression surface. After checking that the correct die size is being used,
begin compressing on the outer aluminum tube at the opposite end of the eye/clevis at the "Start" knurl.

CAUTION
Clean dies and sufficient but not excessive lubrication are the most important factors in applying proper compressions and
avoiding curvature.

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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

8 Begin compressions on the jumper terminal

inside the knurl on the end opposite the jumper Start Here Compress to End
pad. Overlap compressions by 1/3 to 1/2 of their
length in the direction of the jumper pad to ensure
complete compression.

Knurl Mark

9 Continue to compress until the compressions meet

the inside of the knurl closest to the jumper pad.

PACKAGE COMPONENTS
DEAD-END JUMPER

1. Dead-End Assembly Tools Required:

2. Jumper Terminal • Torque Wrench
3. Hardware • Wrench
• Joint Compound
(not included)

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 SP3457-6 - COMPRESSION DEAD-END & JUMPER TERMINAL FOR ACCC & ULS ACCC CONDUCTORS

DEAD-END JUMPER ASSEMBLY

1 Check that the pad connections are free from

damage and residue. Thoroughly clean the pads of
both the dead-end and the jumper terminal with a
wire brush to remove any oxidation.

2 Coat the dead-end terminal pad with conductive

electrical joint compound (not included). Spread
the compound evenly over the pad to ensure
total coverage.

CAUTION
DO NOT use inhibitor (grease) compound that
is used to coat the inner hardware before
compressions.

3 Place a flat washer onto each bolt and thread

through the pad. On the opposite side, apply the
other flat washer, then lockwasher, then nut, and
hand-tighten. Once tight, torque the bolts to at least
40 ft-lb (54 Nm), revisiting each bolt several times
to ensure that the pad is fully compressed and that
all bolts are tightened to the proper specification.

4 Completed Dead-End and Jumper Terminal

assembly.

11
GLOBAL HEADQUARTERS +1 440 461 5200
660 BETA DRIVE [email protected]
CLEVELAND, OH 44143 PLP.COM

© 2023 Preformed Line Products

SP3457-6