TE Connectivity 1490406-1 User manual

Instruction Sheet
1 of 10
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408-8704
02 JAN 17 Rev B
Crimping Die
Wire Size
(AWG)
Head or Tool
Part Number
Color Code Dot
Hydraulic Crimping Heads
Hydraulic Hand Tool(s)
1490597-1
Red
8
1490745-1, 1490746-1, 1490747-1, 1976230-1(1)
1490748-1, 1490749-1
1490598-1
Blue
6
1490599-1
Yellow
4
1490406-1
Red
2
1490746-1, 1976230-1(1)
1490749-1
1490700-1
Blue
1/0
(1) Not to be used for splices
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.
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.
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 Assemblies;
PN 1490406-1, PN 1490597-1, PN 1490598-1,
PN 1490599-1, and PN 1490700-1

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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 that the moving and stationary dies are properly oriented.
3.2. Die Removal
Ensure that the possibility of accidental activation of the hydraulic power unit has been eliminated, and proceed
as follows:
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 in the ram is exposed.
3. Depress the release button and slide the indenter out of the ram.

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4. CRIMPING PROCEDURE
4.1. Crimping Terminals
DANGER
Avoid personal injury. When operating tool or power unit, exercise caution while holding terminals or wire near the crimping
area.
1. Strip wire to the dimensions listed in Figure 3. DO NOT nick or cut the wire strands.
Wire Size
(AWG)
Wire Strip Length
TERMINYL Terminal and Splice
Terminal
Splice
8
7.96-9.53 [.313-.375]
15.48-17.07 [.609-.672]
6
11.18-12.70 [.440-.500]
19.45-20.24 [.766-.797]
4
11.18-12.70 [.440-.500]
19.45-21.03 [.766-.828]
2
11.43-13.08 [.450-.515]
21.83-30.18 [.859-1.188]
1/0
18.54-20.24 [.730-.797]
28.58-30.18 [1.125-1.188]
2/0
18.54-20.24 [.730-.797]
28.58-30.18 [1.125-1.188]
3/0
19.05-20.64 [.750-.813]
28.58-30.18 [1.125-1.188]
4/0
19.45-21.03 [.766-.828]
28.58-30.18 [1.125-1.188]
Figure 3
2. Select the proper color-coded terminal for the wire size (the wire size stamped on the terminal tongue
and on the crimping die must match the wire size selected).
3. Insert stripped wire fully into terminal wire barrel.
The end of the conductor must not protrude more than 1.60 mm [.063 in.] beyond the edge of the wire
barrel.
CAUTION
DO NOT turn or twist the wire or terminal during insertion.
4. Place the terminal in the stationary die with the edge of the wire barrel resting against the locator and
the bottom of the terminal tongue facing the stationary die (see Figure 4).
5. Holding the wire in place, activate tool or power unit to complete crimp.
NOTE
If terminal sticks in the die after crimping, apply a rocking action to the terminal to loosen it from the die. Wipe light oil on the
dies to prevent sticking, or spray dry lubricant.
6. Inspect the crimp according to Section 5.

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Figure 4
4.2. Crimping Splices
DANGER
Avoid personal injury. When operating tool or power unit, exercise caution while holding splice or wire near the crimping area.
1. Strip wires to the dimensions listed in Figure 3. DO NOT nick or cut the wire strands.
2. Select the proper color-coded splice for the wire size (the wire size stamped on the splice and on the
crimping die must match the wire size selected).
3. Insert the stripped wire into the wire barrel of the end of the splice to be crimped until the wire bottoms
against the wire stop within the splice.
4. Place the splice in the stationary die. Grasp the end of the splice to be crimped and point the opposite
end toward the top of the head yoke at approximately a 30 degree angle. Rotate the end of the splice
to be crimped into the die. Position the edge of the window indent against the locator. Refer to Figure
5.
Figure 5
5. Holding wire in place, activate tool or power unit to complete the first wire barrel crimp.

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6. When crimp is completed, remove the latch pin, open the yoke and remove the splice.
NOTE
If splice sticks in the die after crimping, apply a rocking action to the terminal to loosen it from the die. Wipe light oil on the
dies to prevent sticking, or spray dry lubricant.
7. To crimp the other half of splice, reposition un-crimped end of splice in the stationary die and follow
the same procedure used to crimp the first half of splice.
8. Inspect the crimp according to Section 5.
4.3. Crimping Splices with Step-Down Adapter
DANGER
Avoid personal injury. When operating tool or power unit, exercise caution while holding splice or wire near the crimping area.
1. Strip wires to the dimensions listed in Figure 3. DO NOT nick or cut the wire strands.
2. Select the proper splice, adapter, and crimping die for the wire size (see Figure 6).
*Note that the end of the splice containing the adapter has a different color code. Use the crimping die
for the larger wire size to crimp both ends of the splice. For example, use Crimping Die PN 1490598–
1 (for wire size 6 AWG) to crimp both ends of the splice with step-down adapter for stepping down
from wire size 6 to 8 AWG.
Wire Size (AWG)
Step
Crimping Die
Die and Splice
Color Code
Step-Down Adapter
Color Code
8 to 12-10
1490597-1
Red
Yellow
6 to 8
1490598-1
Blue
Red
Figure 6
3. Insert stripped wire into the wire barrel of the end of the splice to be crimped until the wire bottoms
against the wire stop within the splice. Refer to Figure 3.
4. Remove crimping head latch pin and open yoke.
5. Place the splice in the stationary die. Grasp the end of the splice to be crimped and point the opposite
end toward the top of the head yoke at approximately a 30 degree angle. Rotate the end of the splice
to be crimped into the die. Position the edge of the window indent against the locator. Refer to Figure
5.
6. Holding the splice in place, close the yoke and insert the latch pin.
CAUTION
Be sure the latch pin is fully inserted, or damage to the dies and tool or head will occur when activated.
7. Holding the wire in place, activate tool or power unit to complete first wire barrel crimp.
8. When the crimp is completed, remove the latch pin, open the yoke and remove splice.
NOTE
If splice sticks in the die after crimping, apply a rocking action to the terminal to loosen it from the die. Wipe light oil on the
dies to prevent sticking, or spray dry lubricant.
9. To crimp the other half of splice, reposition un-crimped end of splice in the stationary die and follow
the same procedure used to crimp the first half of splice.
10. Inspect the crimp according to Section 5.
Step-Down Adapter

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5. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the features described in Figure 7. Use only the terminals
and splices that meet the conditions shown in the “ACCEPT” column.
Figure 7

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6. MAINTENANCE / INSPECTION
DANGER
To avoid personal injury, ALWAYS release hydraulic pressure to hose or control and disconnect power unit from power supply
before performing maintenance or inspection procedure.
Each crimping die is thoroughly inspected before packaging. Since there is a possibility of damage during
shipment, the crimping die should be inspected immediately upon arrival at your facility.
Regular inspections should be performed by quality control personnel. A record of scheduled inspections
should remain with the dies and/or be supplied to supervisory personnel responsible for the dies. Though
recommendations call for at least one inspection a month, the inspection frequency should be based on the
amount of use, ambient working conditions, operator training and skill, and established company standards.
CAUTION
Regular inspections should include checking torque setting of (4) screws in accordance with Figure 8.
Crimping Die
PN
Wire Size
(AWG)
Screw Torque Setting
Specification
(inch-pounds)
1490597-1
8
28
1490598-1
6
28
1490599-1
4
28
1490406-1
2
28
1490700-1
1/0
49
Figure 8
Torque (4) Screws in
Accordance with Figure 8.

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6.1. 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. Remove dust, dirt, and other contaminants with a clean brush, or a soft, lint--free cloth. Do NOT use
objects that could damage the dies.
2. Make certain the dies are protected with a THIN coat of any good SAE 20 motor oil. Do not oil
excessively.
3. When the dies are not in use, mate them and store in a clean, dry area.
6.2. Visual Inspection
1. Remove all lubrication and accumulated film by immersing the dies in a suitable commercial
degreaser that will not affect paint or plastic material.
2. Make sure all die components are in place. If replacements are necessary, refer to the replacement
parts listed in Figure 11.
3. Check components for wear. Remove and replace worn components.
4. Inspect the crimp area for flattened, chipped, cracked, worn, or broken areas. If damage is evident,
the dies must be repaired before returning them to service (see Section 7, REPLACEMENT AND
REPAIR).
6.3. Gaging the Crimping Chamber
The die closure inspection is accomplished using plug gages. A suggested gage design and the GO and NO-
GO diameters of the plug gage elements are shown in Figure 9.
Figure 9

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The following procedure is recommended for inspecting the die closures:
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 crimping chamber. Push element straight into the crimping chamber
without using force. The GO element must pass completely through the crimping chamber as shown
in Figure 10.
3. Align the NO-GO element and try to insert it straight into the crimping chamber. The NO-GO element
may start entry but must not pass completely through as shown in Figure 10.
If the crimping chamber conforms to the gage inspection, the crimping die is considered dimensionally correct
and should be lubricated with a THIN coat of SAE 20 motor oil.
If the crimping chamber DOES NOT conform to the gage inspection not, the dies must be repaired before
returning them to service (see Section 7, REPLACEMENT AND REPAIR).
For additional information concerning the use of a plug gage, refer to Instruction Sheet 408-7424.
Figure 10
7. REPLACEMENT AND REPAIR
The parts listed in Figure 11 are customer-replaceable. A complete inventory can be stocked and controlled to
prevent lost time when replacement of parts is necessary. Order replacement parts through your TE
Connectivity 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)
TE CONNECTIVITY CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105—3608
NOTE
Dies may be returned for evaluation and repair.
For die repair service, contact a TE Representative at 1-800-526-5136.

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8. REVISION SUMMARY
Add screw torque and LOCTITE application to process; resulting in a new Figure 8, renumbering of
subsequent Figures, and CAUTIONS in SECTIONS 6 and 8.
Replacement Parts
Item
Part Number for Crimping Die Assembly
Description
Qty
Per
Assy
1490597-1
1490598-1
1490599-1
1490406-1
1490700-1
1
1490407-4
1490407-3
1490407-2
1490407-1
1490407-5
Die, Moving
1
2
1490353-4
1490353-3
1490353-2
1490353-1
1490353-5
Die,
Stationary
1
3
1490357-3
1490357-2
1490357-1
1490791-3
1490791-2
Locator
1
4
8-21000-8
1-21000-9
2-21000-0
4-306105-4
3-21000-0
Screw
2
5
21018-5
21018-6
Nut
2
6
4-306105-5
2-306105-5
2-21000-2
4-306105-6
6-305927-4
Screw
2
7
1490356-7
1490356-6
1490356-5
1490356-1
1490356-8
Plate, Flare
1
8
----
----
----
1490356-4
1-1490356-1
Plate, Flare,
Lower
1
9
----
----
----
1490356-3
1-1490356-0
Plate, Flare,
Upper
1
10
1490356-7
1490356-6
1490356-5
1490356-2
1490356-9
Plate, Flare
1
CAUTION
Apply LOCTITE THREADLOCKER BLUE 242 or LOCTITE THREADLOCKER BLUE 243 to threads of items 4, 5, and 6.
Torque screws to applicable specification in Figure 8.
Figure 11
LOCTITE, THREADLOCKER BLUE 242, and THREADLOCKER BLUE 243 are trademarks.