TE Connectivity 90260-1 User manual

Insulation Crimp
Adjustment Lever
Front of Tool
(Contact Side)
Contact Support
Crimpers
Anvils
Ratchet
©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*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.
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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
i
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

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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

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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.

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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]
12
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
121045-3 Ring, Retaining 4
221045-6 Ring, Retaining 2
Figure 5