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 90Bend 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 nil es. - 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