408-7235
2 of 4
Rev H
each marked on the BACK side of the tool with the
letters A and B. The wire size range is marked on the
link. See Figure 1.
The locator positions the receptacle in the jaws and
aids in locating the wire in the receptacle. The
insulation adjustment pin is used to regulate the crimp
height of the insulation barrel of the receptacle. The
ratchet assures full crimping of the receptacle. Once
engaged, the ratchet will not release until the tool
handles have been FULLY closed.
The jaws bottom before the ratchet releases. This
design feature ensures maximum electrical and
tensile performance of the crimp. DO NOT
re-adjust the ratchet.
3. CRIMPING PROCEDURE
Select the appropriate receptacle and wire size for the
hand tool. The wire size and insulation diameter must
be within the specified range for the receptacle. Strip
the wire to the length shown in Figure 2. DO NOT nick
or cut the wire strands. Then, proceed as follows:
Figure 2
1. Hold tool so that the BACK side is facing you.
2. Open the jaws by squeezing the tool handles
together until the ratchet releases.
3. Center the receptacle wire barrel in the
appropriate nest of the anvil jaw (refer to Figure 1).
Make sure the tool locator enters the receptacle
locator slot. See Figure 3.
4. Holding the receptacle in place, squeeze the tool
handles together just enough to hold the receptacle
in the jaws.
Squeezing the handles together too much will
deform the wire barrel.
5. Insert the stripped wire into the receptacle
insulation barrel and through the wire slot of the tool
locator until the wire insulation butts against the
locator. See Figure 3.
6. Holding the wire in place, squeeze the tool
handles together until the ratchet releases.
7. Allow the tool handles to open FULLY and
remove the crimped receptacle from the tool.
Figure 3
4. INSULATION CRIMP ADJUSTMENT
Each tool has three insulation adjustment positions to
adjust the wire insulation grip: 1-Small, 2-Medium, and
3-Large. To determine the proper insulation crimp
setting, proceed as follows:
1. Insert the adjustment pin into Position 3 as shown
in Figure 1.
2. Position the receptacle into the jaws as described
in Section 3, CRIMPING PROCEDURE.
3. Insert an UNSTRIPPED wire into just the
insulation barrel of the receptacle. Crimp the
receptacle and remove it from the jaws.
4. Check the insulation support by bending the wire
back and forth once. The insulation barrel should
retain grip on the wire insulation. If the wire pulls
out, move the insulation adjustment pin to the next
smaller position (2) and perform another test crimp.
If the wire does not pull out, the pins are properly
adjusted.
Move the insulation adjustment pin as necessary until
the desired insulation grip is obtained. The crimp
should hold the wire insulation firmly without cutting
into it.
HAND TOOL
STRIP LENGTH
90165-1
7.14 [.281]
90166-1, 90166-2
6.35 [.250]
CAUTION
!
Locator Slot
Insulation Barrel
Wire Barrel
Wire Strip Length
(See Table)
CAUTION
!
Back Side
of Tool
Locator
Wire Slot
Receptacle
Locator Slot
Nest of
Anvil Jaw
Stripped
Wire
