Instruction Sheet

Crimping Die Assemblies

408--8703

LOC B

1 of 6

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company

*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

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

1583094--1 1490351--3 1490352--3 2 52,600--83,700 26.7--42.4

1490746--1

1490748--1

1583095--1 1490351--4 1490352--4 1/0 83,700--119,500 42.4--60.6

1976230--1

1583096--1 1490351--5 1490352--5 2/0 119,500--150,500 60.6--76.3

1583097--1 1490351--6 1490352--6 3/0 150,500--190,000 76.3--96.3

1490746--1

1583098--1 1490351--7 1490352--7 4/0 190,000--231,000 96.3--117

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

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

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

Part #	149035-1
Description
Category	MICROCIRCUITS
Availability	In Stock
Qty	9

Qty	Price
1 - 1	$50.58240
2 - 3	$40.23600
4 - 5	$37.93680
6 - 7	$35.25440
8 +	$31.42240

149035-1

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