408-8908 Datasheet, PDF (2/6 Pages) Tyco Electronics – Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.

408-8908
1. INTRODUCTION
This instruction sheet provides application
instructions, maintenance, and inspection procedures
for the dies listed in Figure 1. These dies crimp
SOLISTRAND Flag Terminals to solid or stranded
copper wire (also listed in Figure 1).
The dies are used in Hydraulic Head 1490746-1 and
Hydraulic Hand Tool 1490749-1. Refer to Figure 1.
NOTE
i
All dimensions on this document are in metric units
[with U. S. customary units in brackets]. Figures are
for reference only and are not drawn to scale.
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
use with the die assembly.
CAUTION ^{Never operate the tool with the dies removed.}
!
Nest
Die Release Button
Indenter
Ram (Advanced)
Figure 2
2. Activate the power unit until the lower die release
button (located in the ram) is exposed.
3. Depress the release button and slide the indenter
out of the ram.
4. WIRE STRIPPING AND CRIMPING PROCEDURE
DANGER
AVOID PERSONAL INJURY. Exercise extreme
caution when operating crimping head and holding
STOP terminals or wire near the crimping dies.
3.1. Die Installation (Figure 2)
DANGER
STOP
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 release button located in the
"C"-head.
2. Slide the nest into place in "C"-head. See
Figure 2.
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 2.
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 2)
1. Depress the upper release button located in the
"C"-head and slide the nest out of the head.
4.1. Wire Stripping
Obtain the correct wire, flag terminal, and crimping
tool (with correct die assembly installed) for your
application. Strip wire insulation to the dimensions
indicated in Figure 3, taking care not to nick or cut
conductor(s), and proceed as follows:
4.2. Crimping Procedure
1. Ensure that wire size stamped on flag terminal
corresponds to wire size being used in the
application and wire size stamped on nest and
indenter.
2. Center flag terminal wire barrel in die nest. When
crimping flag terminals, hold tongue of flag
terminals against nest as shown in Figure 4. If
terminal locator is present, slide terminal into
terminal locator and press the tongue of the flag
terminal against the slope on the nest.
3. Activate power unit so that ram advances and
holds terminal in place but DOES NOT deform wire
barrel.
4. Insert stripped wire into terminal until end of
conductor is flush with or extended slightly beyond
end of wire barrel. See Figure 3.
5. Activate power unit to complete crimp.
Rev A
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