Instruction Sheet
Hydraulic Hand Crimping
Tool 1490748-1
408-8716
06 OCT 10 Rev A
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.
Moving Die
Release Button
“C” Head
Striker (Sown in Actuated
Position to Depress Plunger)
Movable
Lever
Stationary Die
Release Button
Ram(Shown Advanced)
Plunger
Stationary
Lever
Figure 1
1. INTRODUCTION
Hydraulic Hand Crimping Tool 1490748-1 (Figure 1) is
designed for crimping the terminals and splices in
Figure 2. Read these instructions thoroughly before
using the hand tool.
TERMINALS
AMPOWER*
Terminals and Splice
SOLISTRAND*
Terminals And Splices
TERMINYL*
Terminals and splices
WIRE SIZE
(AWG)
6 Through 3/0
8 Through 4/0
8 Through 4
Figure 2
INSTRUCTION
SHEET
408-8703
408-8691
408-8704
The hand tool has a stationary lever and a movable
lever. These levers are compressed to pump hydraulic
fluid behind the ram, moving it forward and thereby
closing the dies. After the crimping is complete, the
movable lever is turned to depress the plunger. The
moving die retracts to its original position, completing
the crimping cycle.
3. DIE INSERTION AND REMOVAL
CAUTION
To avoid damage to the tooling, never operate the
tool with the dies removed. Failure to insert the dies
before operation can result in damage to the "C"-
!
head or the tool ram.
1. Advance ram slightly to gain access to moving
die release button.
2. Before inserting dies, refer to instruction sheet
packaged with dies for detailed instructions:
insert or remove dies, as necessary, by following
procedures given in the instruction sheet for the
dies.
NOTE
i
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures and illustrations are for identification only
and are not drawn to scale.
4. CRIMPING PROCEDURE
1. Strip wires to dimensions specified on the
instructions packaged with dies (see Figure 2).
2. DESCRIPTION
See Figure 1.
©2010 Tyco Electronics Corporation, Berwyn, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
All Rights Reserved
PRODUCT INFORMATION 1-800-522-6752
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
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2. Insert the terminal or splice in stationary die
according to instruction sheet packaged with
dies.
DANGER
To avoid personal injury, be sure to exercise
caution while holding terminals, splices, or wire in
STOP
the crimping area.
3. Pump movable lever until moving die grips
terminal or splice.
CAUTION
Do not deform wire barrel of terminal or splice.
!
4. Insert stripped wire into wire barrel of terminal
or splice.
5. Continue pumping movable lever. A slight click
may be heard, indicating the pump has shifted
into the high-pressure stage. Continue pumping
movable lever and completely crimp the
connector. This tool has a built-in by-pass
cartridge that will automatically activate when full
pressure is reached. There will be a noticeable
decrease in handle pressure when the by-pass is
reached.
NOTE
A high pitched squeaking sound is normal when the
tool is operating in the high pressure stage,
5.1. Daily Maintenance
1. Immerse the hand tool (levers partially closed)
in a reliable commercial degreasing compound to
remove accumulated dirt, grease, and foreign
matter. When degreasing compound is not
available, wipe the tool clean with a soft, lint-free
cloth. Do NOT use hard or abrasive objects that
could damage the tool.
2. Protect all pins, pivot points, and bearing
surfaces with a THIN coat of any good grade
SAE‡ 20 motor oil. Do NOT oil excessively.
3. When the tool is not in use, keep the levers
closed to prevent objects from becoming lodged
in the dies. Store the tool in a clean dry area.
5.2. Periodic Inspection
Though recommendations call for at least one
inspection a month, actual frequency depends on:
•
The care, amount of use, and handling of the hand
tool.
•
The presence of abnormal amounts of dust and
dirt.
•
The degree of operator skill, and
A. Lubrication
•
Your own established standards.
i
Keep all pins, pivot points, and bearing surfaces
lubricated with SAE 20 motor oil as follows:
- Tool used in daily production-lubricate daily
- Tool used daily (occasionally)-lubricate weekly
- Tool used weekly-lubricate monthly
Wipe excess oil from tool, particularly from crimping
area. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
NOTE
A slight weeping of oil from the ram and pump
seals is normal and required to keep the moving
parts lubricated. Excessive leakage indicates a
need for seal replacement. Refer to Section 6,
RETURN/REPLACEMENT.
6. Turn movable lever (to actuate striker), and
compress levers to depress plunger. Movable die
will now retract. See Figure 1.
7. Remove the crimped terminal or splice.
NOTE
If terminal or splice sticks in die after crimping,
apply a rocking action to remove it from die.
i
8. Inspect the crimped terminal or splice
according to inspection procedure on instruction
sheet packaged with the dies.
i
5. MAINTENANCE AND INSPECTION
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations.
The hand tool is inspected before being shipped;
however, It is recommended that the tool be inspected
immediately upon arrival at your facility to ensure that
the tool has not been damaged during shipment.
B. Visual Inspection
1. Make certain all retaining pins are in place and
secured with retaining rings. If replacements are
necessary, return the tool for repair. See Section
6, RETURN/REPLACEMENT.
2. Inspect for worn, cracked, or broken areas. If
damage is evident, return the tool for evaluation
and repair as described in Section 6, RETURN/
REPLACEMENT.
C.Crimping Pressure Inspection
‡ SAE is a trademark of SAE International Corporation. Society of Automotive Engineering.
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408-8716
C. Crimping Pressure Inspection
Check the crimping pressure to ensure that dies are
fully bottomed before pressure is reduced by the
internal bypass valve. The inspection should be
performed using each set of dies that will be used in
the tool.
1. Install dies according to Section 3, DIE
INSERTION AND REMOVAL, and the instruction
sheet packaged with the dies.
2. Select wire and terminal or splice for dies
being used.
3. Place terminal or splice in dies according to
instruction sheet packaged with dies.
4. Perform crimping procedure as described in
Section 4, CRIMPING PROCEDURE, Steps 3
through 5. Do not release hydraulic pressure at
this time.
5. Check the clearance between bottoming
surfaces of crimping dies. If clearance is 0.025
mm [.001 in.] or less, the crimp pressure is
satisfactory. If clearance exceeds 0.025 mm [.001
in.], the crimp pressure is not considered
satisfactory. See Section 6, RETURN/
REPLACEMENT.
If the tool conforms to these inspection procedures,
lubricate it with a THIN coat of any good grade SAE
20 motor oil and return it to service.
6. RETURN/REPLACEMENT
Order replacement parts through your Tyco
Electronics representative, or call 1-800-526-5142, or
send a facsimile of your purchase order to 1-717-986-
7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Crimping heads may also be returned for evaluation
and repair. For tool repair service, contact a Tyco
Electronics representative at 1-800-526-5136.
7. REVISION SUMMARY
Since the previous release of these instructions, the
TE logo was applied.
150mm
[5.9 In.]
(Closed)
585 mm
[23 In.}
Weight: 6.2 kg [13.7 lb]
Figure 3
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