Tyco Electronics 1490748-1 Bedienungsanleitung

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names might be trademarks of their respective owners.

Instruction Sheet

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

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LOC B

Hydraulic Hand Crimping

Tool 1490748-1 408-8716

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.

Figure 1

1. INTRODUCTION

Hydraulic Hand Crimping Tool 1490748-1 (Figure 1) is

designed for crimping the terminals and splices in

Figure 2. Read these instructions thoroughly before

using the hand tool.

Figure 2

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Figures and illustrations are for identification only

and are not drawn to scale.

2. DESCRIPTION

See Figure 1.

The hand tool has a stationary lever and a movable

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

movable lever is turned to depress the plunger. The

moving die retracts to its original position, completing

the crimping cycle.

3. DIE INSERTION AND REMOVAL

To avoid damage to the tooling, never operate the

tool with the dies removed. Failure to insert the dies

before operation can result in damage to the "C"-

head or the tool ram.

1. Advance ram slightly to gain access to moving

die release button.

2. Before inserting dies, refer to instruction sheet

packaged with dies for detailed instructions:

insert or remove dies, as necessary, by following

procedures given in the instruction sheet for the

dies.

4. CRIMPING PROCEDURE

1. Strip wires to dimensions specified on the

instructions packaged with dies (see Figure 2).

TERMINALS WIRE SIZE

(AWG)

INSTRUCTION

SHEET

AMPOWER*

Terminals and Splice 6 Through 3/0 408-8703

SOLISTRAND*

Terminals And Splices 8 Through 4/0 408-8691

TERMINYL*

Terminals and splices 8 Through 4 408-8704

NOTE

CAUTION

“C” Head

Moving Die

Release Button

Striker (Sown in Actuated

Position to Depress Plunger)

Movable

Lever

Stationary Die

Release Button Ram(Shown Advanced) Plunger Stationary

Lever

408-8716

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Rev A

2. Insert the terminal or splice in stationary die

according to instruction sheet packaged with

dies.

To avoid personal injury, be sure to exercise

caution while holding terminals, splices, or wire in

the crimping area.

3. Pump movable lever until moving die grips

terminal or splice.

Do not deform wire barrel of terminal or splice.

4. Insert stripped wire into wire barrel of terminal

or splice.

5. Continue pumping movable lever. A slight click

may be heard, indicating the pump has shifted

into the high-pressure stage. Continue pumping

movable lever and completely crimp the

connector. This tool has a built-in by-pass

cartridge that will automatically activate when full

pressure is reached. There will be a noticeable

decrease in handle pressure when the by-pass is

reached.

A high pitched squeaking sound is normal when the

tool is operating in the high pressure stage,

6. Turn movable lever (to actuate striker), and

compress levers to depress plunger. Movable die

will now retract. See Figure 1.

7. Remove the crimped terminal or splice.

If terminal or splice sticks in die after crimping,

apply a rocking action to remove it from die.

8. Inspect the crimped terminal or splice

according to inspection procedure on instruction

sheet packaged with the dies.

5. MAINTENANCE AND INSPECTION

It is recommended that a maintenance and inspection

program be performed periodically to ensure

dependable and uniform terminations.

The hand tool is inspected before being shipped;

however, It is recommended that the tool be inspected

immediately upon arrival at your facility to ensure that

the tool has not been damaged during shipment.

5.1. Daily Maintenance

1. Immerse the hand tool (levers partially closed)

in a reliable commercial degreasing compound to

remove accumulated dirt, grease, and foreign

matter. When degreasing compound is not

available, wipe the tool clean with a soft, lint-free

cloth. Do NOT use hard or abrasive objects that

could damage the tool.

2. Protect all pins, pivot points, and bearing

surfaces with a THIN coat of any good grade

SAE‡ 20 motor oil. Do NOT oil excessively.

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.

5.2. Periodic Inspection

Though recommendations call for at least one

inspection a month, actual frequency depends on:

•The care, amount of use, and handling of the hand

tool.

•The presence of abnormal amounts of dust and

dirt.

•The degree of operator skill, and

•Your own established standards.

A. Lubrication

Keep all pins, pivot points, and bearing surfaces

lubricated with SAE 20 motor oil as follows:

- Tool used in daily production-lubricate daily

- Tool used daily (occasionally)-lubricate weekly

- Tool used weekly-lubricate monthly

Wipe excess oil from tool, particularly from crimping

area. Oil transferred from the crimping area onto

certain terminations may affect the electrical

characteristics of an application.

A slight weeping of oil from the ram and pump

seals is normal and required to keep the moving

parts lubricated. Excessive leakage indicates a

need for seal replacement. Refer to Section 6,

RETURN/REPLACEMENT.

B. Visual Inspection

1. Make certain all retaining pins are in place and

secured with retaining rings. If replacements are

necessary, return the tool for repair. See Section

6, RETURN/REPLACEMENT.

2. Inspect for worn, cracked, or broken areas. If

damage is evident, return the tool for evaluation

and repair as described in Section 6, RETURN/

REPLACEMENT.

C.Crimping Pressure Inspection

DANGER

STOP

CAUTION

NOTE

‡ SAE is a trademark of SAE International Corporation. Society of Automotive Engineering.

408-8716

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Rev A

C. Crimping Pressure Inspection

Check the crimping pressure to ensure that dies are

fully bottomed before pressure is reduced by the

internal bypass valve. The inspection should be

performed using each set of dies that will be used in

the tool.

1. Install dies according to Section 3, DIE

INSERTION AND REMOVAL, and the instruction

sheet packaged with the dies.

2. Select wire and terminal or splice for dies

being used.

3. Place terminal or splice in dies according to

instruction sheet packaged with dies.

4. Perform crimping procedure as described in

Section 4, CRIMPING PROCEDURE, Steps 3

through 5. Do not release hydraulic pressure at

this time.

5. Check the clearance between bottoming

surfaces of crimping dies. If clearance is 0.025

mm [.001 in.] or less, the crimp pressure is

satisfactory. If clearance exceeds 0.025 mm [.001

in.], the crimp pressure is not considered

satisfactory. See Section 6, RETURN/

REPLACEMENT.

If the tool conforms to these inspection procedures,

lubricate it with a THIN coat of any good grade SAE

20 motor oil and return it to service.

6. RETURN/REPLACEMENT

Order replacement parts through your Tyco

Electronics 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)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

Crimping heads may also be returned for evaluation

and repair. For tool repair service, contact a Tyco

Electronics representative at 1-800-526-5136.

7. REVISION SUMMARY

Since the previous release of these instructions, the

TE logo was applied.

Figure 3

150mm

[5.9 In.]

(Closed)

585 mm

[23 In.}

Weight: 6.2 kg [13.7 lb]

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