Instruction Sheet Crimping Dies for SOLISTRAND* 408-8691 Terminals and Splices 06 NOV 14 Rev G 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. Crimping Dies for SOLISTRAND Terminals and Splices Indenter Nest DIES NOMINAL WIRE SIZE 2 TYPICAL mm TOOL OR PRODUCT [CMA RANGE] HEAD NUMBER 2 NEST INDENTER mm AWG 1490413-1▪ 1490414-1▪ 6.637-10.539 1-1490413-4† 7-8 8 33463 / RTT♦ [13,100-20,800] 1490413-9● 1490414-2● 1490413-2▪ 1490414-2▪ Head Number 10.539-16.771 1-1490413-5† 13-15 6 33466 / RTT♦ [20,800-33,100] 1901820-1 1-1490413-0● 1490414-2● 1901821-1 1490413-3▪ 1490747-1 1490414-2▪ 16.771-26.653 1-1490413-6† 21 4 34323 / BS [33,100-52,600] 1-1490413-1● 1490414-2● Hydraulic Hand Tool Number 1490413-4▪ 1490414-2▪ 26.653-42.411 1-1490413-7† 1490748-1 34-35 2 35187 / PS [52,600-83,700] 1490749-1 1-1490413-2● 1490414-3● 1490413-5▪ 1490414-3▪ 42.411-60.551 1-1490413-8† Hydraulic 59-60 1/0 36946 / PS [83,700-119,500] Battery Tools 1-1490413-3● 1490414-3● 2280116-1, -2 1490413-6 60.551-72.259 2161171-1, -2 67-70 2/0 36948 / PS 1-1490413-9† [119,500-150,500] 2280308-1, -2 1490413-7 72.259-96.274 1490414-3 80-95 3/0 36927 / RTT♦ 2-1490413-0† [150,500-190,000] 1490413-8 96.274-117.049 100-125 4/0 36932 / RTT♦ 2-1490413-1† [190,000-231,000] ▪Also used for STRATO-THERM* Heat Resistant Uninsulated Terminals ♦RTT = Ring Tongue Terminals BS = Butt Splice PS = Parallel Splice ●Dies for Heavy Duty Terminals †90°Bend Terminals Figure 1 1. INTRODUCTION This instruction sheet provides application instructions, maintenance, and inspection procedures for the dies listed in Figure 1. These dies crimp SOLISTRAND ring tongue terminals, butt splices, and parallel splices to solid or stranded copper wire (also listed in Figure 1). The dies are used in Hydraulic Heads 1901820-1, 1901821-1, 149047-1; Hydraulic Hand Tools 1490748-1, 1490749-1; and Hydraulic Battery Tools 2280116-[ ], 2161171-[ ], 2280308-[ ]. Refer to Figure 1 and Figure 2. NOTE All dimensions on this document are in metric units [with U. S. customary units in brackets]. Figures and illustrations are for reference only and are not drawn to scale. Reason for revision is given in Section 7, REVISION SUMMARY. © 2014 TE Connectivity family of companies TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 7 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS 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 - CAUTI O N - Hydraulic Head Hydraulic Head - - elect r ical lines. - W ARNI NG - - 1901820-1 1490747-1 - - Hydraulic Head 1901821-1 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. 2 of 7 Rev G 408-8691 Die Release Die Release Nest Button 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. 3 of 7 Rev G 408-8691 Terminal Butt Splice Parallel Splice B B B NOTE: “B” Equals Wire Barrel STRIP LENGTHS NOMINAL 2 mm WIRE SIZE RING TONGUE TERMINALS BUTT SPLICES PARALLEL SPLICES [CMA RANGE] 2 mm AWG MIN MAX MIN MAX MIN MAX 6.637-10.539 8.334 9.128 10.319 11.112 10.319 11.112 7-8 8 [13,100-20,800] [.328] [.359] [.406] [.437] [.406] [.437] 10.539-16.771 9.922 13.255 11.906 12.700 11.112 11.906 13-15 6 [20,800-33,100] [.391] [.522] [.469] [.500] [.437] [.469] 16.771-26.653 11.509 12.302 13.493 14.288 13.493 14.288 21 4 [33,100-52,600] [.453] [.484] [.531] [.563] [.531] [.563] 26.653-42.411 13.096 13.890 15.081 15.875 15.081 15.875 34-35 2 [52,600-83,700] [.516] [.547] [.594] [.625] [.594] [.625] 42.411-60.551 59-60 1/0 [83,700-119,500] 18.653 20.240 15.875 17.462 17.462 19.050 [.734] [.797] [.625] [.687] [.687] [.750] 60.551-72.259 67-70 2/0 [119,500-150,500] 72.259-96.274 19.050 20.637 17.463 19.050 17.463 19.050 80-95 3/0 [150,500-190,000] [.750] [.812] [.687] [.750] [.687] [.750] 96.274-117.049 19.446 20.637 17.463 19.050 19.050 20.637 100-125 4/0 [190,000-231,000] [.776] [.812] [.687] [.750] [.750] [.812] Figure 4 Inspection Holes of Terminal or Butt Splice Terminal Must Face Either Die End of Wire Visible Brazed Through Inspection Hole Seam Butt Splice (Typ) Terminal or Splice Centered in Ends of Wires Flush with Next Parallel Splice or Extended Beyond End of Barrel 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. 4 of 7 Rev G 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 affect paint or plastic. 5 of 7 Rev G 408-8691 2. Check all surfaces for wear. Inspect the crimp area for flattened, chipped, cracked, worn, or broken areas. If damage is evident, the die must be replaced. Flattened Broken Pitted Chipped Figure 7 Gaging the Crimping Chamber (Figures 8 and 9) The inspection requires the use of a plug gage conforming to the dimensions in Figure 9. TE Connectivity does not manufacture or market these gages. Proceed as follows: 1. Mate the dies until it is evident that they have bottomed. Hold the dies in this position. 2. Align the GO element with the wire barrel crimping chamber. Push the element straight into the crimping chamber without using force. The GO element must pass completely through the crimping chamber. 3. Align the NO-GO element and try to insert it straight into the same crimping chamber. The NO-GO element may start entry but must not pass completely through. If the crimping chamber conforms to the gage inspection, the dies are considered dimensionally correct. If not, they must be replaced. For additional information regarding the use of a plug gage, refer to Instruction Sheet 408-7424. 6. REPLACEMENT PARTS When replacement of a die becomes necessary, contact your local TE Representative; call 1-800-526-5142; 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 7. REVISION SUMMARY  Added new Hydraulic Battery Tool part numbers to table in Figure 1 and INTRODUCTION “GO” Element Must Pass “NO-GO” Element May Completely Through the Enter Partially, But Must Die Closure Not Pass Completely Through the Die Closure Die Bottomed But Not Under Pressure Figure 8 6 of 7 Rev G 408-8691 Die Closure “C” “B” Configuration Dim. Typ GO Dim. “B” NO-GO Dim. “A” Dim. “R” “R” 50.80 [2.000] Typ DIE CLOSURE GAGE ELEMENT DIES “C” RADIUS DIMENSION “A” DIMENSIONS “B” DIMENSION “R” NEST INDENTER GO NO-GO GO NO-GO 1490413-1 2.54-2.548 2.689-2.692 1490414-1 2.54 [.1000] 2.692 [.1060] 7.92 [.312] 3.18 [.125] 1-1490413-4 [.1000-.1003] [.1059-.1060] 1490413-2 1490414-2 3.911-3.919 4.112-4.115 1-1490413-5 3.911 [.1540] 4.115 [.1620] 11.09 [.437] 4.34 [.171] [.1540-.1543] [.1619-.1620] 1490413-9 1490414-2 1490413-3 1490414-2 4.699-4.706 4.899-4.902 1-1490413-6 4.699 [.1850] 4.902 [.1930] 11.09 [.437] 5.54 [.218] [.1850-.1853] [.1929-.1930] 1-1490413-0 1490414-2 1490413-4 1490414-2 5.410-5.418 5.610-.5.613 1-1490413-7 5.410 [.2130] 5.613 [.2210] 11.09 [.437] 6.35 [.250] [.2130-.2133] [.2209-.2210] 1-1490413-1 1490414-2 1490413-5 6.172-6.179 6.372-6.375 1-1490413-8 1490414-3 6.172 [.2430] 6.375 [.2510] 11.09 [.437] 7.52 [.296] [.2430-.2433] [.2509-.2510] 1-1490413-2 1490413-6 6.959-6.967 7.160-7.163 1-1490413-9 1490414-3 6.959 [.2740] 7.163 [.2820] 14.27 [.562] 8.33 [.328] [.2740-.2743] [2819-.2820] 1-1490413-3 1490413-7 7.823-7.830 8.023-8.026 1490414-3 7.823 [.3080] 8.026 [.3160] 9.525 [.375] [.3080-.3083] [.3159-.3160] 2-1490413-0 14.27 [.562] 1490413-8 8.788-8.796 8.989-8.991 1490414-3 8.788 [.3460] 8.991 [.3540] 10.693 [.421] [.3460-.3463] [.3539-.3540] 2-1490413-1 Figure 9 7 of 7 Rev G