408-8704

Crimping Die Assemblies

Rev A

4 of 7

Tyco Electronics Corporation

Step-Down

Adapter

Splices with Step-Down Adapter

WIRE SIZE

(AWG)

STEP

CRIMPING

DIE

DIE AND

SPLICE

COLOR CODE

STEP-DOWN

ADAPTER

COLOR CODE

8 to 12-10

1490597-1

RED

Yellow

6to8

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

_ 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.

Be sure that the latch pin is fully inserted, or

damage to the dies and tool or head will occur

when the tool is activated.

7. Holding the wire in place, activate tool or power

unit to complete first wire barrel crimp.

8. When crimp is completed, remove the latch pin,

open the yoke and remove splice.

If splice sticks in die after crimping, apply a

rocking action to the splice to remove it from the

die. Wipe light oil on dies to reduce sticking, or

use spray dry lubricant.

9. To crimp the other half of splice, reposition

uncrimped 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.

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.

6. MAINTENANCE/INSPECTION

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.

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 10.

3. Check components for wear. Remove and

replace worn components.

CAUTION

!

NOTE

i

DANGER