Tyco Electronics 90015, 90016 Instruction Sheet
Instruction Sheet
1.02--2.0
3
Blueand
Y
1.52--2.5
4
Whi
t
d
2.03--2.9
2
408--1538
25 AUG 10 Rev LHand Crimping Tools 90015 and 90016
PROPER USE GUIDELINES
Cumulative Trauma Disorders can resultfromthe prolonged useof manually powered hand tools. Hand tools areintended for occasional useand low volume
applications. A wide selection of powered application equipment for extended--use, production operations is available.
Tool Part
Back Side
of Tool
Color Code
Marking
Wire Size
Marking (Ref)
Number (Ref)
Terminal
Locator
Crimping
Jaws
SIZE
(AWG)
26
24--22
26
20--18
16
CERTI--CRIMP*
Tool Ratchet
Insulation Crimping
Adjustment Pins
WIRE TERMINAL HAND TOOL
INSULATION
DIA (mm [in.])
1.02--2.03
[.040--.080]
2.03--2.92
[.080--.115]
1.52--2.54
[.060--.100]
2.03--2.92
[.080--.115]
STRIP LENGTH
(mm [in.])
3.96 [.156]
4.75 [.187]
BASE PART
NUMBER
42927 Short
66059 Long
42574 Short
42633 Long
66129 Long Black
42575 Short
42634 Long
42637 Short
42646 Long
SHOULDER
LENGTH
SLEEVE
COLOR
Blue
ellow
White
Black
PART
NUMBER
90015
90016
COLOR
CODE
Blue and
Yellow
ean
Black
CRIMP DOT
CODE
1
2
Figure 1
1. INTRODUCTION
NOTE
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Hand Crimping Tools 90015 and 90016 crimp the
i
PIDG* taper pin terminals (listed in Figure 1) onto
wire sizes 26 through 16 A WG. Read these
instructions thoroughly before crimping any terminals.
E2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics ar e trademarks.
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
1 of 5
LOC B
Hand Crimping Tools 90015 and 90016
408- 1538
2. DESCRIPTION
Each hand tool features two crimping jaws, a terminal
locator, two insulation crimping adjustment pins, and
a CERTI--CRIMP tool ratchet. The hand tool has the
tool part number , color code, and wire size marked on
the BACK side of the tool. The color code must match
the color of the terminal sleeve. The terminal locator
positions the terminal between the crimping jaws and
is adjustable to accommodate long or short shoulder
terminals. The insulation crimping adjustment pins are
used to regulate the crimp height of the insulation
barrel sleeve.
The ratchet assures full crimping of the terminal.
Once engaged, the ratchet will not release until the
tool handles have been FULL Y closed. See Figure 1.
CAUTION
!
The crimping jaws bottom before the
CERTI--CRIMP tool ratchet releases. This design
feature ensures maximum electrical and tensile
performance of the crimp. Do NOT re--adjust the
ratchet.
3. CRIMPING PROCEDURE
NOTE
i
Refer to Figure 1 and select the appropriate wire size
and terminal for the hand tool. The wire size and
insulation diameter must be within the specified range
for the terminal and hand tool.
The tool is coated with a preservative to prevent
rust or corrosion. Wipe this preservative from the
tool, particularly from the crimping jaws, before
using the tool.
1. Strip the wire using the appropriate strip--length
dimension provided in Figure 1. Do NOT nick or
cut the wire strands.
2. Adjust the terminal locator to accommodate the
shoulder length of the terminal being crimped. See
Figure 2.
3. Hold tool so that the BACK side of the tool is
facing you.
4. Open the crimping jaws by squeezing the tool
handles together until the CERTI--CRIMP ratchet
releases.
5. Insert the tip of the terminal through the hole in
the locator. The shoulder of the terminal must be
positioned against the locator as shown in
Figure 2.
6. Hold terminal in position and squeeze the tool
handles together just enough to hold the terminal in
the crimping jaws.
CAUTION
!
7. Insert stripped wire through the insulation barrel
sleeve and into the wire barrel sleeve until it
bottoms. See Figure 2.
8. Hold wire in place and squeeze tool handles
together until the CERTI--CRIMP ratchet releases.
Allow tool handles to open FULLY.
Squeezing the handles together too much will
engage the crimping jaws and deform the
terminal.
Tip of Terminal
Inserted Through
Hole in Locator
Shoulder of Short Shoulder
Terminal Against Locator
Terminal Locator
Adjusted for Short
Shoulder Terminals
Stripped
Wire
Back Side
of Tool
Figure 2
Tip of Terminal
Inserted Through
Hole in Locator
Shoulder of Long Shoulder
Terminal Against Locator
Terminal Locator
Adjusted for Long
Shoulder Terminals
Back Side
of Tool
Stripped
Wire
Rev L2 of 5 Tyco Electronics Corporation
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