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149035-1

Part # 149035-1
Description
Category MICROCIRCUITS
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Technical Document


DISCLAIMER: The information provided herein is solely for informational purposes. Customers must be aware of the suitability of this product for their application, and consider that variable factors such as Manufacturer, Product Category, Date Codes, Pictures and Descriptions may differ from available inventory.

Instruction Sheet
Crimping Die Assemblies
408--8703
LOC B
1 of 6
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TE Connectivity , TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
TOOLI NG ASSISTANCE CENT ER 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.te.com
18 APR 11 Rev B1583092- 1 through 1583098- 1
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume
applications. A wide selection of powered application equipment for extended--use, production operations is available.
Indenter
Nest
Crimping Die Assemblies for AMPOWER* Terminals and Splices
CRIMPING DIES WIRE SIZE HYDRAULIC CRIMP TOOLING
ASSEMBLY INDENTER NEST AWG CMA RANGE mm
2
HEADS HAND TOOLS
1583092--1 1490351--1 1490352--1 6 20,800--33,100 10.5--16.8
1583093--1 1490351--2 1490352--2 4 33,100--52,600 16.8--26.7
1490745--1
1
4
9
0
7
4
6
1
1
4
9
0
7
4
8
1
1583094--1 1490351--3 1490352--3 2 52,600--83,700 26.7--42.4
1490746--1
1
4
9
0
7
4
7
--
1
1490748--1
1
4
9
0
7
4
9
--
1
1583095--1 1490351--4 1490352--4 1/0 83,700--119,500 42.4--60.6
1
4
9
0
7
4
7
--
1
1976230--1
1
4
9
0
7
4
9
--
1
1583096--1 1490351--5 1490352--5 2/0 119,500--150,500 60.6--76.3
1
9
7
6
2
3
0
1
1583097--1 1490351--6 1490352--6 3/0 150,500--190,000 76.3--96.3
1490746--1
1
4
9
0
7
4
9
1
1583098--1 1490351--7 1490352--7 4/0 190,000--231,000 96.3--117
1
4
9
0
7
4
6
1
1976230--1
1490749--1
Figure 1
1. INTRODUCTION
This instruction sheet covers application and
maintenance procedures for the AMPOWER
Crimping Die Assemblies listed in Figure 1. The die
assemblies are used in Hydraulic Heads 1490745--1,
1490746--1, 1490747--1, 1976230--1 (not to be used
with splices), and Hydraulic Hand Tools 1490748--1
and 1490749--1. See Figures 1 and 3.
Basic instructions for the installation and removal of
dies are covered in Section 3; wire preparation and
crimping procedures are covered in Section 4; and
Maintenance and Certification are covered in
Section 6.
All dimensions on this document are in metric
units [with U.S. customary units in brackets].
Figures and illustrations are for identification only
and are not drawn to scale.
Read these instructions carefully prior to installing,
removing, or using the dies.
2. DESCRIPTION
TheAMPOWERdieassemblieslistedinthetablein
Figure 1 are used to crimp AMPOWER terminals and
splices. Wire strip length is provided in Figure 2.
The die assemblies are single position sets, each
consisting of an anvil subassembly and an indenter
subassembly.
Refer to Figure 1 to ensure compatibility of crimping
dies and wire size. For instructions relative to the
crimping head and the hydraulic power units, refer to
the instructions packaged with them.
ORIGINAL INSTRUCTI O NS
NOTE
i
408- 8703
Rev B2 of 6
Wire Strip Lengths
Length of Barrel “B” Plus 1.6 [.062] 1/16
(Except Terminals and Butt Splices)
B +1.6 [.062] 1/16
B +1.6 [.062] 1/16
B +1.6 [.062] 1/16
B
B
B
B
BBBB
Figure 2
3. DIE INSERTION AND REMOVAL
Do not operate the tool without the dies.
AVOID PERSONAL INJURY. When changing
dies, exercise caution and avoid accidentally
depressing foot switch or trigger controls of
power units.
3.1. Die Insertion
Refer to Figures 1 and 3 for a listing of tooling that
these dies will fit into. Ensure that the possibility of
accidental activation of the hydraulic power unit has
been eliminated, and proceed as follows:
1. Depress the upper release button located in the
C--head and slide the nest into place.
2. Release the button and rock the die
back--and--forth until the nest snaps in place.
3. Activate the power unit until the lower die
release button located in the ram is exposed.
4. Depress the release button and slide the
indenter into place.
5. Release the button and rock the indenter
back--and--forth until the die snaps in place.
6. Return the ram to the down position.
Figure 3
Hydraulic Head
1490745--1
Tools Using Crimping Dies for A MPOW ER
Terminals and Splices (Refer to Figure 1)
Hydraulic Head
1490746--1
Hydraulic Head
1490747--1
elec tr ic al li nes.
WARNING
CAUTION
--
--
--
--
--
--
--
--
--
Hydraulic Hand
Tool 1490749--1
Hydraulic Hand
Tool 1490748--1
CAUTION
!
DANGER
408- 8703
3 of 6Rev B
3.2. Die Rem oval
Ensure that the possibility of accidental activation of
the hydraulic power unit has been eliminated, and
proceed as follows:
1. Depress the upper release button located in the
C--head and slide the nest out of the head.
2. Activate the power unit until the lower die
release button in the ram is exposed.
3. Depress the release button and slide the
indenter out of the ream.
4. WIRE PREPARATION AND CRIMPING PROCEDURES
4.1. Wire Pr eparation
1. Select proper size terminal or splice for wire size
being used.
2. Determine correct terminal or splice wire loading
by referring to CMA (Circular Mill Area) range listed
in the table in Figure 1. The total CMA of wires
being used must be within the CMA range of the
terminal or splice.
3. Strip the wire to the dimensions indicated in the
table in Figure 2, taking care not to nick or cut the
wire strands.
4.2. Crimping Procedure
1. Ensure that the wire size stamped on the
terminal or splice corresponds to the wire size
stamped on the stationary die.
2. Center the terminal or splice in the stationary die
as shown in Figure 4.
3. Activate the power unit so that the moving die
advances and holds the terminal or splice in place
without deforming the wire barrel.
4. Insert the stripped wire until it bottoms in the
terminal or butt splice. The end of the wire must be
visible through the sight hole.
Sight holes of butt splices must always face
either the upper or lower die.
5. When inserting the stripped wires into a parallel
splice, the ends of the wires must be at least flush
with, or extend slightly beyond the end of the wire
barrel.
6. Activate the power unit to complete the crimp.
7. To crimp the other half of the butt splice, remove
and reposition the uncrimped half in the stationary
die. Insert the wire until it bottoms against the
splice sire stop (visible through the sight holes),
and then crimp the splice.
8. Inspect the crimp by referring to Section 5,
CRIMP INSPECTION, and to Figure 5.
Figure 4
Terminal Butt Splice
Parallel Splice
End of Inserted Wire
Must Be Visible
Through Sight Hole
Center Terminal Wire
Barrel in Stationary Die
Ends of Inserted Wires
Must be Visible
Through Sight Holes
Center Half of Butt Splice in
Stationary Die (Sight Holes
Must Face Upper or Lower Die)
Center Parallel Splice
in Stationary Die
NOTE
i
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