Hand Crimping Tools 46447, 47410,
49592, 49935, 69363, 525693, 574573,
1490046-1 and 1490047-1
Instruction Sheet
408-1542
10 Mar 11 Rev N
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use a
low volume applications. A wide selection of powered application equipment for extended-use, production operations is available.
Wire Size
Marking
CERTI-CRIMP*
Tool Ratchet
CAUTION
The crimping jaws bottom before the ratchet
releases. This feature ensures maximum electrical
and tensile performance of the crimp. Do NOT
!
re-adjust the ratchet
3. CRIMPING PROCEDURE
Strip the wire according to the dimensions listed in
Figure 2. The strip length is determined by the type of
terminal or splice and by the wire size. Do not nick or
cut the wire strands. Proceed as follows:
1. Close the tool handles until the ratchet
releases. Allow the tool handles to open fully.
2. Center the terminal or splice wire barrel in the
appropriate crimping chamber. For terminals,
make sure that the flat side of the tongue faces
the anvil or the nest; for splices, make sure that
the brazed seam (when visible) is toward the
indenter or, the nest. See Figure 3.
3. While holding the terminal or splice in place,
squeeze the tool handles together just until the
jaws begin to close on the wire barrel. Do NOT
deform the wire barrel.
4. Insert the stripped wire into the wire barrel,
making sure that the wire insulation does not
enter the wire barrel.
5. While holding the wire in place, squeeze the
tool handles together until the ratchet releases,
then allow the tool handles to open fully.
6. To crimp the other half of a butt splice, position
the uncrimped wire barrel in the crimping
chamber, and repeat the crimping procedure.
NOTE
If splice cannot be turned for crimping other half,
turn the tool around.
1 Crimping
Chambers
(Typical)
2 Crimping
Chambers
(Typical)
Figure 1
3 Crimping
Chambers
(Typical)
1. INTRODUCTION
Hand Crimping Tools 46447, 47410 (crimps 12-10
AWG terminals on a 45° angle), 49592, 49935, 69363,
525693, 574573, 1490046-1, and 1490047-1 (shown
in Figure 1) are used to crimp SOLISTRAND* and
STRATO-THERM* terminals and splices (listed in
Figure 2) onto stranded wire sizes 26 through 10
AWG.
Read these instructions thoroughly before using the
tool.
NOTE
Dimensions in this instruction sheet are in
millimeters [with inch equivalents in brackets].
Figures and illustrations are for reference only, and
are not drawn to scale.
i
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
This document supersedes Instruction Sheet
411-1099.
i
NOTE
2. DESCRIPTION
Each tool consists of a CERTI-CRIMP tool ratchet and
two crimping jaws (indenter and anvil) containing one,
two, or three crimping chambers. Each tool is marked
with the wire size range for each crimping chamber.
See Figure 1. Full crimping of the terminal or splice is
assured by the CERTI-CRIMP tool ratchet. Once
engaged, the ratchet does not release until the tool
handles have been FULLY closed.
i
Terminals and splices can also be rotated 180°
with the seam toward the nest.
4. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 4. Poor crimps can be
avoided by carefully following the procedures
provided in Section 3, and by following the tool
maintenance procedures provided in Section 5.
©2010 Tyco Electronics Corporation, Berwyn, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
All Rights Reserved
PRODUCT INFORMATION 1-800-522-6752
TE logo and Tyco Electronics are trademarks
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
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
408-1542
Hand Tool
Wire Size
(AWG)
Range
(and
Terminal
Size)
22-16
Wire Strip Length
Crimping
Chamber
Marked
Terminal
(Standard)
Terminal
(Long Barrel)
Butt
Splice
Parallel
Splice
22-16
16-14
12-10
14-12
22-16
46447
16-14
12-10
4 37- 5.16 [172 203]
6.35-7.14 [.250-.281]
4.37-5.16 [.172-.203]
4.37-5.16 [.172-.203]
-----
6.35-7.14 [.250-.281]
7.94-8.73 [.313-.344]
4959252
49935
525693
574573
49935
525693
574573
1490046-1
47410
49935
525693
574573
1490047-1
14-12
22-16
-----
6.35-7.14 [.250-.281]
6.35-7.14 [.250-.281]
------
7.94-8.73 [.313-.344]
16-14
16-14
4.37-5.16 [.172-.203]
6.35-7.14 [.250-.281]
6.35-7.14 [.250-.281]
7.94-8.73 [.313-.344]
12-10
12-10
6.35-7.14 [.250-.281]
-----
6.35-7.14 [.250-.281]
-----
26-24
69363
22-20
24-20
26-24
22-20
22-20
3.17-3.97 [.125-.156]
4.37-5.16 [.172-.203]
-----
-----
-----
------
3.57-4.37 [.141-.172]
5.16-5.95 [.203-.234]
4.37-5.16 [.172-.203]
-----
-----
-----
Figure 2
5. MAINTENANCE AND INSPECTION
The tool is inspected before being shipped, however
TE recommends that the tool be inspected
immediately upon arrival at your facility to ensure that
the tool has not been damaged during shipment.
Frequency of inspection depends on:
1. The care, amount of use, and handling of the
hand tool.;
2. The presence of abnormal amounts of dust
and dirt.;
3. The degree of operator skill; and
4. Your own established standards.
5.1. Daily Maintenance
1. Remove dust, moisture, and other
contaminants with a clean brush, or a soft, lint--
free cloth. Do NOT use objects that could
damage the tool.
2. Make certain that the retaining pins are in
place and that they are secured with retaining
rings.
3. All pis, pivot points, and bearing surfaces
should be protected with a thin coat of any good
SAE 20 motor oil. Do NOT oil excessively.
4. When the tool is not in use, keep handles
closed to prevent objects from becoming lodged
in the crimping jaws. Store the tool in a clean,
dry area.
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408-1542
Terminals and Splices Can Also Be Rotated 180° with the Seam Toward the Nest
Figure 3
5.2. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with SAE 20 motor oil as follows:
Tools used in daily production - lubricate daily
Tools used daily (occasional) - lubricate weekly
Tools 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.
Remove traces of oil or dirt from the crimping
chambers and plug gage.
4. Close the tool handles until it is evident that
the jaws have bottomed; then hold in this
position. Do NOT force the jaws beyond initial
contact.
5. 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.
6. Align the NO-GO element and try to insert it
straight into the same crimping chamber. The
NO-GO element may start entry, but must not
pass completely through the crimping chamber.
NOTE
The jaws in Tools 49935 and 574573 are not
symmetrically located; make sure that the tool
conforms to the symmetry requirements shown in
Figure 8.
5.3. Periodic Inspection
1. The tool should be immersed (handles
partially closed) in a reliable commercial
degreasing compound to remove accumulated
dirt, grease, and foreign matter.
2. Close tool handles until ratchet releases and
then allow them to open freely. If they do not
open quickly and fully, the spring is defective and
must be replaced. See Section 6,
REPLACEMENT AND REPAIR.
3. Inspect head assembly for worn, cracked, or
broken jaws. Refer to Figure 5. If damage is
evident, return the tool to TE for evaluation and
repair. See Section 6, REPLACEMENT AND
REPAIR.
i
If the crimping chambers conforms to the gage
inspection, the tool is considered dimensionally
correct, and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If not, the tool must be
returned for further evaluation and repair. Refer to
Section 6, REPLACEMENT AND REPAIR.
For additional information regarding the use of a plug
gage, refer to Instruction Sheet 408-7424.
5.4. Gaging the Crimping Chambers
This inspection requires the use of a plug gage
conforming to the dimensions provided in Figure 6
and Figure
TE does not manufacture or market these gages. To
gage the crimping chambers, proceed as follows:
Rev
N
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408-1542
Suggested Plug Gage Design
NO-GO
Dim
Jaw Closure
Configuration
Figure 4
5.5. Ratchet Inspection
The CERTI-CRIMP tool ratchet should be checked to
ensure that the ratchet does not release prematurely,
allowing the jaws to open before they have fully
bottomed. Obtain a 0.025 mm [.001 in.] shim suitable
for checking the clearance between the bottoming
surfaces of the crimping jaws. Proceed as follows:
1. Select a terminal or splice, and properly
stripped
wire with
maximum
wire load (such as wire
size 16
AWG and size 22-16 terminal).
2. Position the terminal or splice and wire
between the crimping jaws, as described in
Section 3.
3. Hold the wire in place and squeeze the
handles until the CERTI-CRIMP tool ratchet
releases. Hold the handles in this position,
maintaining just enough tension to keep the jaws
closed.
Rev
N
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NOT12--10
Tool
Crimp
Chmbr
Mrkng
22-16
Gage Element Dimensions
GO
1.295-1.303
[.0510-.0513]
1.498-1.506
[,0590-.0593]
2.108--2.116
[.0830-.0833]
1.752--1.760
[.0690--0693]
1.168--1.176
[.0460-.0463]
1.371--1.379
[.0540-.0543]
NO-GO
1.445--1.447
[.0569--.0570
1.648--1.651
[.0649-.0650]
2.258--2.260
[.0889-.0890]
1.902-1.905
[.0749-.0750]
1.318-1-.320
[.0519-.0520]
1.521-1.524
[.0599-.060]
“R”
1.57
[.062]
1.57
[.062]
2.36
[.093]
1.57
[.062]
1.57
[.062]
1.98
[.078]
2.76
[.109]
46447
16-14
12-10
49592
4995
525623
49935
525693
1490046-1
14-12
22-16
16-14
Figure 5
47410
49935
525693
1490047-1
12-10
1.930-1.938
[.0760-.076]
0.660-0.668
[.026-.0263]
0.939-0.947
[.037-.0373]
1.295-1.303
[.051--.0513]
1.498--1.506
[.059--.0593]
2.108-2.116
[.083--.0833
2.080-2.082
[.0819-.082]
0.810-0.812
[.0319-.032]
1.089-1.092
.0429-.043]
1.445--1.447
1.648--1.651
[.0649--.065]
2.258-2.260
[.0889--.089
4. Check the clearance between the bottoming
surfaces of the crimping jaws. If the clearance is
0.025 mm [.001 in.] or less, the ratchet is
satisfactory. If clearance exceeds 0.025 mm
[.001 in.], the ratchet is out of adjustment and
must be repaired. See Section 6,
REPLACEMENT AND REPAIR.
26-24
69363
22-20
22-16
574573
16-14
12-10
1.003
[.0395]
1.19
[.047]
1.57.
[.062
1.57
[.062]
2.36
[.093]
Figure 8
Figure 6
Figure 9
Figure 7
Rev
N
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