TE Connectivity 90260-1 Manuel utilisateur

Insulation Crimp

Adjustment Lever

Front of Tool

(Contact Side)

Contact Support

Crimpers

Anvils

Ratchet

*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

1of 4

Instruction Sheet

TOOLING ASSISTANCE CENTER

1-800-722-1111



PRODUCT INFORMATION

1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com LOC B

408-7484



Hand Crimping Tool 90260-1 07 SEP 11 Rev B

PROPER USE GUIDELINES

Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use

and low volume applications. A wide selection of powered application equipment for extended-use, production operations is available.

Figure 1

1. INTRODUCTION

Hand Crimping Tool 90260-1 is designed to crimp the

Type XI loose piece (LP) contacts listed in Figure 2.

Read these instructions thoroughly before crimping

any contacts.

NOTE

All dimensions in this document are in metric units

[withU.S.customaryunitsinbrackets].Figuresand

illustrations are for identification only and are not

drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 7, REVISION SUMMARY.

2. DESCRIPTION (Figure 1)

This tool features two fixed dies (crimpers), two

movable dies (anvils), an insulation crimp adjustment

lever, a contact locator/insulation stop, a contact

support, and a ratchet.

The insulation crimp adjustment lever is used to

regulate the crimp height of the contact insulation

barrel. For detailed information on using the

adjustment lever, refer to Section 4, INSULATION

CRIMP ADJUSTMENT.

The contact locator/insulation stop positions the

contact between the crimping dies. In addition, the

locator/insulation stop aids in locating the wire in the

contact. In use, it rests in the contact locator slot. See

Figures 2 and 3.

The contact support prevents the contact from

bending during the crimping operation.

The ratchet ensures full crimping of the contact. Once

engaged, the ratchet will not release until the tool

handles have been fully closed.

CAUTION

The crimping dies bottom before the ratchet

releases. This is a design feature that assures

maximum electrical and tensile performance of the

crimp. Do NOT re-adjust the ratchet.

Wire Barrel Insulation Barrel

Locator Slot Wire Strip Length

4.37 [.171]

WIRE CRIMP SECTION

(Wire Size

Marking)

CONTACT NO.

SIZE

(AWG) INSUL

DIA LP STRIP

22 to 24

1.58

[.062]

22 - 24 203802-3†

203802-4†

203816-3‡

203816-4‡

203816-5‡

203802-1†

203802-2†

203816-1‡

203816-2‡

203816-6‡

20 20

† Socket ‡ Pin

Figure 2

408-7484

2of 4

Rev B

3. CRIMPING PROCEDURE

Refer to the chart in Figure 2 and select wire within the

specified wire size and insulation diameter. Strip the

wire to the length indicated -do NOT cut or nick the

wire strands.

Notice that each crimp section has the applicable wire

size stamped above it. Use this marking and the wire

size that you are using to determine the proper crimp

section.

Select the applicable loose-piece contact and proceed

as follows:

1. Hold the tool so that the back (wire side) is 

facing you.

2. Make sure that the ratchet is released. Squeeze

the tool handles together and allow them to open

fully.

3. Looking straight into the back of the tool, insert

the contact (insulation barrel first) into the front of

the appropriate crimp section. See Figure 3.

4. Position the contact in the crimpers so that the

locator/insulation stop enters the locator slot in the

contact.

5. Hold the contact in this position and squeeze the

tool handles together until the insulation anvil starts

entry into the insulation crimper. Do NOT deform the

insulation barrel or wire barrel.

6. Insert a properly-stripped wire through the wire

slot of the locator and into the wire barrel of the

contact until the wire insulation butts against the

locator/insulation stop.

7. While holding the wire in place, squeeze the tool

handles together until the ratchet releases.

8. Allow the tool handles to open fully and remove

the crimped contact.

4. INSULATION CRIMP ADJUSTMENT

The insulation barrel crimp height is regulated by the

insulation crimp adjustment lever. To determine the

proper setting, test crimp a contact using the setting

which approximates the insulation size: (1) small, (2)

medium, or (3) large. If the crimped insulation barrel is

too tight or too loose, change the setting accordingly.

The crimp should hold the insulation firmly without

cutting into it.

5. MAINTENANCE/INSPECTION

5.1. Daily Maintenance

Remove all foreign particles with a clean, soft brush or

a clean, soft, lint-free cloth. Make sure the proper

retaining pins are in place and are secured with the

proper retaining rings. If foreign matter cannot be

removed easily, or if the proper replacement parts are

not available, return the tool to your supervisor.

Back of Tool

(Wire Side)

Crimp Section

Wire Size Marking

Insulation

Crimper

Stripped

Wire

Insulation

Anvil

Locator Slot

in Contact

Contact Support

Locator / Insulation

Stop

Insulation Crimp

Adjustment Lever

Figure 3

408-7484

3of 4

Rev B

Make sure all pivot points and bearing surfaces are

protected with a thin coat of any good SAE 20 motor

oil. Do NOT oil excessively. When the tool is not in

use, keep the handles closed to prevent objects from

becoming lodged between the dies, and store the tool

in a clean, dry area.

5.2. Periodic Inspection

Regular inspection should be performed by quality

control personnel. A record of scheduled inspections

should remain with the tool and/or be supplied to the

supervisory personnel responsible for the tool. Though

recommendations call for at least one inspection a

month, the inspection frequency should be based on

the amount of use, ambient working conditions,

operator training and skill, and established company

standards. These inspections should be performed in

the following sequence:

A. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the tool (handles partially closed) into a

suitable degreaser that will not affect paint or plastic

material.

2. Make certain all retaining pins are in place and

are secured with the proper retaining rings. If

replacements are necessary, refer to Figure 5.

3. Close the tool handles until the ratchet releases,

and then allow the handles to open freely. If they do

not open quickly and fully, then the spring is

defective and must be replaced (see Section 6,

REPLACEMENT AND REPAIR).

4. Inspect the tool, with special emphasis on

checking for worn, cracked, or broken crimping

dies. If damage to any part of the head is evident,

return the tool for evaluation and repair (see Section

6, REPLACEMENT AND REPAIR).

B. Crimp Height Inspection

Crimp height inspection is performed through the

use of a micrometer with a modified anvil,

commonly referred to as a crimp height comparator. 

TE does not market crimp height comparators.

Refer to Instruction Sheet 408-7424 for detailed

information on obtaining and using a crimp height

comparator.

Proceed as follows:

1. Refer to the chart in Figure 4 and select a contact

and a wire (maximum size) for each crimp section.

2. Refer to Section 3, CRIMPING PROCEDURE,

and crimp the contact(s) accordingly.

3. Using a crimp height comparator, measure the

wire barrel crimp height as shown in Figure 4. If the

crimp height conforms to that shown in the chart,

the tool is considered dimensionally correct. If not,

return the tool for evaluation and repair (refer to

Section 6, REPLACEMENT AND REPAIR).

Modified

Anvil

Position Point on

Center of Wire Barrel

Opposite Seam

“A”

±0.05

[±.002]

CONTACT

NUMBER

(LP)

WIRE SIZE

AWG (Max)

CRIMP SECT

(Wire Size

Marking)

CRIMP

HEIGHT

DIM. “A”

203802

203816 22 24 - 22 0.71 [.028]

20 20 0.86 [.034]

Figure 4

C. Ratchet Inspection

Obtain a 0.025-mm [.001-in.] shim that is suitable for

checking the clearance between the bottoming

surfaces of the crimping dies. Proceed as follows:

1. Select a contact and maximum size wire for the

hand tool.

2. Position the contact and wire between the

crimping dies, as described in Section 3,

CRIMPING PROCEDURE.

3. Holding the wire in place, squeeze the tool

handles together until the ratchet releases. Hold the

handles in this position, maintaining just enough

tension to keep the dies closed.

4. Check the clearance between the bottoming

surfaces of the crimping dies. If the clearance is

0.025 [.001] or less, the ratchet is satisfactory. If the

clearance exceeds 0.025 [.001], the ratchet is out of

adjustment and must be repaired.

If the tool conforms to these inspection procedures,

lubricate it with a thin coat of any good SAE 20 motor

oil and return it to service.

408-7484

4of 4

Rev B

6. REPLACEMENT AND REPAIR

The parts listed in Figure 5 are customer- replaceable.

A complete inventory can be stocked and controlled to

prevent lost time when replacement of parts is

necessary. Order replacement parts through your TE

representative, or call 1-800-526-5142, or send a

facsimile of your purchase order to 1-717-986-7605, or

write to:

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

Tools may be returned for evaluation and repair. For

tool repair service, contact a representative at 

1-800-526-5136.

7. REVISION SUMMARY

Since the previous version of this document, the

following changes were made:

•Updated ratchet description.

•Changed footnote characters in Figure 2.

•Removed crimp height comparator source

information.

•Updated document to corporate requirements.



Do not remove the retaining pins or permanent damage to the tool may result.

CAUTION

19.0 [.75]

63.5 [2.50]

(Closed)

301.8 [11.88]

WEIGHT: 567 g [1 lb 4 oz]

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QTY PER TOOL

121045-3 Ring, Retaining 4

221045-6 Ring, Retaining 2

Figure 5

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