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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.
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)
8
6
4
2
1/0
2/0
3/0
4/0
Wire Strip Length
TERMINYL Terminal and Splice
Terminal
Splice
7.96-9.53 [.313-.375]
15.48-17.07 [.609-.672]
11.18-12.70 [.440-.500]
19.45-20.24 [.766-.797]
11.18-12.70 [.440-.500]
19.45-21.03 [.766-.828]
11.43-13.08 [.450-.515] 21.83-30.18 [.859-1.188]
18.54-20.24 [.730-.797] 28.58-30.18 [1.125-1.188]
18.54-20.24 [.730-.797] 28.58-30.18 [1.125-1.188]
19.05-20.64 [.750-.813] 28.58-30.18 [1.125-1.188]
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.
Step-Down Adapter
Wire Size (AWG)
Step
8 to 12-10
6 to 8
Crimping Die
1490597-1
1490598-1
Die and Splice
Color Code
Red
Blue
Step-Down Adapter
Color Code
Yellow
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.
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