Instruction Sheet Hydraulic Hand Crimping 408-8716 Tool 1490748-1 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. Movable Lever Striker (Sown in Actuated Moving Die Position to Depress Plunger) Release Button C Head Stationary Die Plunger Stationary Release Button Ram(Shown Advanced) Lever Figure 1 The hand tool has a stationary lever and a movable 1. INTRODUCTION 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 Hydraulic Hand Crimping Tool 1490748-1 (Figure 1) is movable lever is turned to depress the plunger. The designed for crimping the terminals and splices in moving die retracts to its original position, completing Figure 2. Read these instructions thoroughly before the crimping cycle. using the hand tool. WIRE SIZE INSTRUCTION 3. DIE INSERTION AND REMOVAL TERMINALS (AWG) SHEET To avoid damage to the tooling, never operate the CAUTION tool with the dies removed. Failure to insert the dies AMPOWER* 6 Through 3/0 408-8703 Terminals and Splice before operation can result in damage to the- head or the tool ram. SOLISTRAND* 8 Through 4/0 408-8691 Terminals And Splices 1. Advance ram slightly to gain access to moving die release button. TERMINYL* 8 Through 4 408-8704 Terminals and splices 2. Before inserting dies, refer to instruction sheet packaged with dies for detailed instructions: Figure 2 insert or remove dies, as necessary, by following Dimensions in this instruction sheet are in metric procedures given in the instruction sheet for the NOTE units with U.S. customary units in brackets . dies. Figures and illustrations are for identification only i and are not drawn to scale. 4. CRIMPING PROCEDURE 1. Strip wires to dimensions specified on the 2. DESCRIPTION instructions packaged with dies (see Figure 2). See Figure 1. 2010 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 3 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. visit our website at www.tycoelectronics.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B408-8716 2. Insert the terminal or splice in stationary die 5.1. Daily Maintenance according to instruction sheet packaged with 1. Immerse the hand tool (levers partially closed) dies. in a reliable commercial degreasing compound to To avoid personal injury, be sure to exercise remove accumulated dirt, grease, and foreign DANGER caution while holding terminals, splices, or wire in matter. When degreasing compound is not STOP the crimping area. available, wipe the tool clean with a soft, lint-free cloth. Do NOT use hard or abrasive objects that could damage the tool. 3. Pump movable lever until moving die grips 2. Protect all pins, pivot points, and bearing terminal or splice. surfaces with a THIN coat of any good grade SAE 20 motor oil. Do NOT oil excessively. Do not deform wire barrel of terminal or splice. CAUTION 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. 4. Insert stripped wire into wire barrel of terminal 5.2. Periodic Inspection or splice. Though recommendations call for at least one 5. Continue pumping movable lever. A slight click inspection a month, actual frequency depends on: may be heard, indicating the pump has shifted into the high-pressure stage. Continue pumping The care, amount of use, and handling of the hand movable lever and completely crimp the tool. connector. This tool has a built-in by-pass The presence of abnormal amounts of dust and cartridge that will automatically activate when full dirt. pressure is reached. There will be a noticeable decrease in handle pressure when the by-pass is The degree of operator skill, and reached. Your own established standards. A high pitched squeaking sound is normal when the A. Lubrication NOTE tool is operating in the high pressure stage, Keep all pins, pivot points, and bearing surfaces i lubricated with SAE 20 motor oil as follows: - Tool used in daily production-lubricate daily 6. Turn movable lever (to actuate striker), and - Tool used daily (occasionally)-lubricate weekly compress levers to depress plunger. Movable die will now retract. See Figure 1. - Tool used weekly-lubricate monthly 7. Remove the crimped terminal or splice. Wipe excess oil from tool, particularly from crimping area. Oil transferred from the crimping area onto If terminal or splice sticks in die after crimping, NOTE certain terminations may affect the electrical apply a rocking action to remove it from die. characteristics of an application. i A slight weeping of oil from the ram and pump NOTE seals is normal and required to keep the moving 8. Inspect the crimped terminal or splice parts lubricated. Excessive leakage indicates a i according to inspection procedure on instruction need for seal replacement. Refer to Section 6, sheet packaged with the dies. RETURN/REPLACEMENT. B. Visual Inspection 5. MAINTENANCE AND INSPECTION 1. Make certain all retaining pins are in place and It is recommended that a maintenance and inspection secured with retaining rings. If replacements are program be performed periodically to ensure necessary, return the tool for repair. See Section dependable and uniform terminations. 6, RETURN/REPLACEMENT. The hand tool is inspected before being shipped 2. Inspect for worn, cracked, or broken areas. If however, It is recommended that the tool be inspected damage is evident, return the tool for evaluation immediately upon arrival at your facility to ensure that and repair as described in Section 6, RETURN/ the tool has not been damaged during shipment. REPLACEMENT. C.Crimping Pressure Inspection SAE is a trademark of SAE International Corporation. 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