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ORIGINAL INSTRUCTIONS
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.
408-8691
Tools Using Crimping Dies for SOLISTRAND
Terminals and Splices (Refer to Figure 1)
Hydraulic Hand
Tool 1490748-1
Hydraulic Hand
Tool 1490749-1
Hydraulic Head
1490747-1
Hydraulic Head
1901821-1
Hydraulic Head
1901820-1
- CAUTI O N
-
-
-
-
el ct r i al l es.
e
c i
n
- W ARNI NG
NOTE:
Hydraulic Battery Tools 2280116-[ ],
2161171-[ ], and 2280308-[ ] Not Shown.
Figure 2
2. DESCRIPTION
Each die assembly consists of a nest and an indenter (ordered separately) which are retained in the crimping
head by retainer pins. The nest is positioned in the yoke of the crimping head, and the indenter is positioned in
the ram of the tool.
3. DIE INSTALLATION AND REMOVAL
Refer to Figure 1 and determine the correct die assembly, wire size, product number, and tool head to be used
together.
CAUTION
Never operate the tool with the dies removed.
3.1. Die Installation
(Figure 3)
DANGER
To avoid personal injury, be sure to exercise extreme caution when using the power unit. Avoid depressing the footswitch or
trigger control when installing or removing dies.
1. Depress the upper die release button located in the “C”-head.
2. Slide the nest into place in “C”-head. See Figure 3.
3. Release the button and rock the die back and forth until the nest snaps into position.
4. Activate the power unit until the lower die release button located in the ram is exposed.
5. Depress the release button.
6. Slide the indenter into position in the ram. See Figure 3.
7. Release the button and rock the indenter back and forth until the die snaps into position.
8. Return ram to the down position.
3.2. Die Removal
(Figure 3)
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 (located in the ram) is exposed.
3. Depress the die release button and slide the indenter out of the ram.
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408-8691
Die Release
Button
Nest
Die Release
Button
Indenter
Ram
(Advanced)
Figure 3
4. WIRE STRIPPING AND CRIMPING PROCEDURES
4.1. Wire Stripping
Strip wire to the dimensions listed in Figure 4. Do NOT nick or cut the wire strands.
4.2. Crimping Procedure
DANGER
To avoid personal injury, be sure to exercise caution while holding terminals, splices or wire near the crimping area of power
units.
1. Ensure that the wire range or size stamped on the terminal or splice corresponds with the wire size
being used and the wire range or size stamped on the nest and indenter.
2. Center terminal or splice in nest as shown in Figure 5. For best results, when brazed seam on terminal
or splice is visible, position seam toward indenter.
3. Activate power unit so that ram advances and holds terminal or splice in place. Do NOT deform
terminal or splice wire barrel.
4. Insert stripped wire into terminal or
parallel splice
until end of conductor is flush with or extended
slightly beyond end of wire barrel.
5. Insert stripped wire into
butt splice
until end of conductor butts against splice wire stop.
6. Activate power unit to complete the crimp.
NOTE
If terminal sticks in die after crimping, grasp wire close to crimp and apply a rocking motion to remove from die.
7. If terminal sticks in die after crimping, grasp wire close to crimp and apply a rocking motion to remove
from die.
8. Refer to Paragraph 5.1, Crimp Inspection, for standard terminal, butt splice, and parallel splice crimp
inspection.
5. INSPECTION/MAINTENANCE
DANGER
To avoid personal injury, disconnect the power supply before performing maintenance, adjustments, inspections and repairs.
5.1. Crimp Inspection
(Figure 6)
NOTE
The accompanying procedure is included as an aid to the tool operator ONLY. It is not intended to serve as a quality control
procedure for qualifying finished crimps on SOLISTRAND terminals or splices.
Inspect crimped terminals or splices by checking the features described in Figure 6. Use only terminals or
splices that meet the conditions shown in the ACCEPT column. Terminals and splices displaying the features
shown in the REJECT column can be avoided by careful use of these instructions and by performing the
maintenance and inspection procedures described in Paragraphs in 5.2 and 5.3.
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408-8691
Terminal
B
Butt Splice
B
Parallel Splice
B
NOTE:
“B” Equals Wire Barrel
NOMINAL
WIRE SIZE
mm
2
7-8
13-15
21
34-35
59-60
67-70
80-95
100-125
AWG
8
6
4
2
1/0
2/0
3/0
4/0
[CMA RANGE]
6.637-10.539
[13,100-20,800]
10.539-16.771
[20,800-33,100]
16.771-26.653
[33,100-52,600]
26.653-42.411
[52,600-83,700]
42.411-60.551
[83,700-119,500]
60.551-72.259
[119,500-150,500]
72.259-96.274
[150,500-190,000]
96.274-117.049
[190,000-231,000]
mm
2
STRIP LENGTHS
RING TONGUE TERMINALS
MIN
8.334
[.328]
9.922
[.391]
11.509
[.453]
13.096
[.516]
18.653
[.734]
19.050
[.750]
19.446
[.776]
MAX
9.128
[.359]
13.255
[.522]
12.302
[.484]
13.890
[.547]
20.240
[.797]
20.637
[.812]
20.637
[.812]
Figure 4
BUTT SPLICES
MIN
10.319
[.406]
11.906
[.469]
13.493
[.531]
15.081
[.594]
15.875
[.625]
17.463
[.687]
17.463
[.687]
MAX
11.112
[.437]
12.700
[.500]
14.288
[.563]
15.875
[.625]
17.462
[.687]
19.050
[.750]
19.050
[.750]
PARALLEL SPLICES
MIN
10.319
[.406]
11.112
[.437]
13.493
[.531]
15.081
[.594]
17.462
[.687]
17.463
[.687]
19.050
[.750]
MAX
11.112
[.437]
11.906
[.469]
14.288
[.563]
15.875
[.625]
19.050
[.750]
19.050
[.750]
20.637
[.812]
Terminal
Inspection Holes of
Terminal or Butt Splice
Must Face Either Die
End of Wire Visible
Through Inspection Hole
Brazed
Seam
(Typ)
Butt Splice
Ends of Wires Flush with
or Extended Beyond End
of Barrel
Parallel Splice
Terminal or
Splice
Centered in
Next
Figure 5
5.2. Daily Maintenance
It is recommended that each operator of the dies be made aware of, and responsible for, the following steps of
daily maintenance:
1. It is recommended that each operator of the dies be made aware of, and responsible for, the following
steps of daily maintenance:
2. If dies are coated with oil or preservative, wipe clean - particularly in the crimping areas - before
placing them in use.
Rev G
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408-8691
Figure 6
3. When dies are not in use, make certain all surfaces are protected with a THIN coat of any good SAE
20 motor oil, and mate and store them in a clean, dry area.
5.3. Periodic Inspection
Regular inspections should be performed by quality control personnel. A record of scheduled inspections
should remain with the dies or be made available to supervisory personnel responsible for the dies. Though
recommendations call for at least a monthly inspection, the inspection frequency should be based upon the
amount of use, working conditions, operator training and skill, and established company standards. These
inspections should be performed in the following sequence:
Visual Inspection
(Figure 7)
1. Remove all lubrication and accumulated film by immersing the dies in a suitable degreaser that will not
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