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408-10034
Terminal
Wire Strip
Length
Strap
Type
Butt Splice
Parallel Splice
Wire
Barrel
Note: Not to Scale
CRIMPING
HEAD
WIRE SIZE
(AWG)
RANGE (and
Terminal Size)
USE TOOL
CRIMPING
CHAMBER
MARKED
TERMINAL
(Standard)
WIRE STRIP LENGTH
TERMINAL BUTT
(Long Barrel) SPLICE
PARALLEL
SPLICE
1-46447-0
22-16
16-14
22-16
16-14
4.37-5.16 [.172-.203]
--
6.35-7.14 [.250-.281]
7.94-8.73 [.313-.344]
12-10
12-10
6.35-7.14 [.250-.281]
1-49935-0
22-16
16-14
22-16
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]
--
26-24
26-24
3.17-3.97 [.125-.156]
--
3.57-4.37 [.141-.172]
1-69363-0
22-20
24-20
22-20
22-20
4.37-5.16 [.172-.203]
--
--
--
5.16-5.95 [.203-.234]
4.37-5.16 [.172-.203]
--
Figure 2
NOTE
1. Remove quick pins from the adapter assembly.
Refer to Figure 1.
2. Insert crimping head into the adapter
assembly.
3. After the crimping head is properly aligned,
insert the quick pins through the two holes in the
adapter and through the holes in the crimp head.
The quick pins will “snap” into position when they
are properly inserted.
i
3.2. Removal
DANGER To avoid personal injury, ALWAYS disconnect the
battery from the tool before removing crimping
STOP head.
Remove the quick pins from the crimping head; then
remove the crimping head from the tool holder.
4. CRIMPING PROCEDURES
DANGER To avoid personal injury, ALWAYS keep fingers
clear of crimping jaws when operating the tool.
STOP Never place anything within the crimping jaws
except Tyco Electronics terminals or splices.
Rev B
1. Strip wire to dimensions shown in Figure 2. DO
NOT nick wire strand or use wires with nicked or
missing conductor strands.
2. Center the terminal or splice wire barrel in the
appropriate crimp chamber. For terminals, make
sure that the flat side of the tongue faces the
anvil. For splices, make sure that the brazed
seam, (when visible), is towards the indenter. See
Figure 3.
3. Depress the trigger to advance the moving
ram. This closes the crimp jaws in order to hold
the terminal in place. DO NOT deform the wire
barrel.
4. Insert stripped wire into terminal or splice
making sure the wire insulation does not enter
the wire barrel.
5. Activate the tool to complete the crimp. The
crimp tool automatically returns to the first
position of the cycle when the crimp is complete.
6. To crimp the other half of the butt splice,
position the uncrimped wire barrel into the
crimping chamber, and repeat the crimping
procedure. If the splice cannot be turned for
crimping the other half, rotate the crimping head.
7. Refer to Section 5 and Figure 4 for crimp
inspection.
2 of 5
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