Instruction Sheet Crimping Die Assemblies PN 1490406-1, PN 1490597-1, PN 1490598-1, 408-8704 PN 1490599-1, and PN 1490700-1 15 NOV 18 Rev E 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 Die Head or Tool Wire Size Part Color Code (AWG) Hydraulic Crimping Hydraulic Hand Number Dot Heads Tool(s) 1490597-1 Red 8 1490745-1, 1490746-1, 1490748-1, 1490598-1 Blue 6 (1) 1490747-1, 1976230-1 1490749-1 1490599-1 Yellow 4 1490406-1 Red 2 (1) 1490746-1, 1976230-1 1490749-1 1490700-1 Blue 1/0 (1) Not to be used for splices Crimping Die Wire Size Battery-Powered Crimping Die Revision Part Color Code (AWG) Crimp Tools Number Dot 1490597-1 Red 8 D or Higher 1490598-1 Blue 6 E or Higher 2280116- 1490599-1 Yellow 4 D or Higher 2161171- 1490406-1 Red 2 C or Higher 1490700-1 Blue 1/0 N/A N/A Figure 1 1. INTRODUCTION The crimping die assemblies listed in Figure 1 crimp TERMINYL* terminals and splices onto wire sizes 8 through 1/0 AWG. Refer to Figure 1 to ensure compatibility of crimping die, head or tool, and wire size. NOTE Dimensions in this document are in millimeters with inches in brackets . Figures and illustrations are for reference only and are not drawn to scale. For detailed information about the head or tool, refer to the instructions packaged with the head or tool. Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY. 2018 TE Connectivity Ltd. family of companies. PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. 1 of 10 All Rights Reserved. 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. 408-8704 2. DESCRIPTION Each crimping die consists of a stationary die (nest) and a moving die (anvil). The stationary die features a locator. Each die contains a color code dot that matches the color code of the terminal and splice. When mated, the dies form a crimping chamber. 3. DIE INSTALLATION AND REMOVAL (FIGURE 2) CAUTION DO NOT operate the tool without the dies. DANGER To avoid personal injury, ALWAYS release hydraulic pressure to hose or control and disconnect power unit from power supply before installing or removing dies. Figure 2 3.1. Die Installation 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. CAUTION To avoid damage to the dies, be sure the moving and stationary dies are properly oriented the color code dots (alignment dots) must be on the same side of the crimping head, as shown in Figure 2. 7. Extend ram SLOWLY while assuring dies align properly as they close, continue to extend ram until dies bottom. 8. Retract ram. 9. SLOWLY extend ram again to make sure the dies align and bottom. 2 of 10 Rev E