TE Connectivity CERTI-CRIMP 90165-1 User manual

©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
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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
408-7235
CERTI-CRIMP* Hand Crimping Tools
90165-1, 90166-1, and 90166-2 26 SEP 11 Rev H
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
CERTI-CRIMP Hand Crimping Tools 90165-1,
90166-1, and 90166-2 are designed to crimp
FASTON* 250 Series Premier Line receptacles onto
wire sizes 22 through 14 AWG. Refer to Figure 1.
Catalog 82004 provides a guide for wire-to-receptacle
selection. For wire sizes and receptacles not listed,
contact PRODUCT INFORMATION at the number at
the bottom of this page for recommendation.
Read these instructions thoroughly before using the
hand tool.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures and illustrations are for reference only and
are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
Each hand tool features two jaws (anvil and indenter),
a locator, an insulation adjustment pin, and a ratchet.
When closed, the jaws form two crimping chambers
Crimping Chamber
Letter Markings
Indenter Jaw
Locator
Anvil Jaw Link
Insulation
Adjustment Pin
Ratchet
Back Side of Tool
TOOL WIRE
PART NUMBER CRIMPING CHAMBER
LETTER MARKING INSULATION DIAMETER RANGE (mm [in.]) SIZE (AWG)
90165-1 A3.05-4.32 [.120-.170] 18
B 16-14
90166-1 A 1.52-2.54 [.060-.100]
22-18
B 2.29-3.30 [.090-.130]
90166-2 A---
B 2.16-3.18 [.085-.125]
NOTE
i
ORIGINAL INSTRUCTIONS

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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
WireStrip Length
(See Table)
CAUTION
!
BackSide
of Tool
Locator
Wire Slot
Receptacle
Locator Slot Nest of
Anvil Jaw
Stripped
Wire

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Rev H
5. MAINTENANCE AND INSPECTION PROCEDURE
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations. Though
recommendations call for at least one inspection a
month, frequency of inspection depends on:
— the care, amount of use, and handling of the
hand tool,
— the presence of abnormal amounts of dust and
dirt,
— the degree of operator skill, and
— your own established standards.
The hand tool is inspected before being shipped;
however, it is recommended that the tool be inspected
immediately upon arrival to ensure that the tool has
not been damaged during shipment.
5.1. Daily Maintenance
1. Hand tool should be immersed (handles partially
closed) in a reliable commercial degreasing
compound to remove accumulated dirt, grease, and
foreign matter. When degreasing compound is not
available, tool may be wiped clean with a soft,
lint-free cloth. DO NOT use hard or abrasive objects
that could damage the tool.
2. Make certain that the retaining pins are in place
and that they are secured with retaining rings.
3. All pins, pivot points, and bearing surfaces should
be protected with a THIN coat of any good SAE 20
motor oil. DO NOT oil excessively.
4. When the tool is not in use, keep handles closed
to prevent objects from becoming lodged in the
jaws. Store the tool in a clean, dry area.
5.2. Periodic Inspection
A. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with SAE 20 motor oil as follows:
Tool used in daily production - lubricate daily
Tool used daily (occasional) - lubricate weekly
Tool used weekly - lubricate monthly
Wipe excess oil from tool, particularly from crimping
area. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
B. Visual Inspection
1. Close the tool handles until the ratchet releases
and then allow them to open freely. If they do not
open quickly and fully, the spring is defective and
must be replaced. See Section 6, REPLACEMENT
AND REPAIR.
2. Inspect the jaws for worn, cracked, or broken
areas. If damage is evident, return the tool for
evaluation and repair. See Section 6,
REPLACEMENT AND REPAIR.
C. 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
manufacture or market crimp-height comparators.
Detailed information on obtaining and using crimp-
height comparators can be found in Instruction Sheet
408-7424.
Proceed as follows:
1. Select a receptacle and maximum size wire for
each crimping chamber.
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the receptacle accordingly.
3. Measure the wire barrel crimp height as shown in
Figure 4. If the crimp height conforms to that height,
the tool is considered dimensionally correct. If not,
return the tool for evaluation and repair. See Section
6, REPLACEMENT AND REPAIR.
Figure 4
D. Ratchet Inspection
1. Select a receptacle and maximum size wire for
the tool.
2. Position the receptacle and wire between the
jaws as described in Section 3, CRIMPING
PROCEDURE.
3. Hold the wire in place and squeeze the handles
until the ratchet releases. Hold the handles in this
position, maintaining just enough tension to keep
the jaws closed.
HAND TOOL MAXIMUM WIRE
SIZE (AWG) CRIMP HEIGHT ±0.10 [±.004]
90165-1 18 1.75 [.069]
14 1.80 [.071]
90166-1 18 1.40 [.055]
90166-2
Position Point on
CenterofWireBarrel
Opposite Seam
Modified
Anvil
Crimp Height
(See Table)

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4. Check the clearance between the bottoming
surfaces of the jaws. If the clearance is 0.025 mm
[.001 in.] or less, the ratchet is satisfactory. If
clearance exceeds 0.025 mm [.001 in.], the ratchet
is out of adjustment and must be repaired. See
Section 6, REPLACEMENT AND REPAIR.
6. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 5. 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 717-986-7605, or
write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For tool evaluation and customer repair service, call
1-800-526-5136.
7. REVISION SUMMARY
•Updated document to corporate requirements
•Changed “Qty Per Tool” amounts in table in
Figure 5
Figure 5
6
12
5
3 4
Weight: 539 g [1 lb 3 oz]
76.2 [3.00] (Closed)
279.4 [11.00]
22.22 [.875]
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
1 21045-3 RING, External Crescent Retaining, .188-in. D Shaft 4
2 8-59558-2 PIN, Retaining, .187-in. D x .521 in. L 2
3 21045-6 RING, External Crescent Retaining, .250-in. D Shaft 2
4 2-23620-9 PIN, Retaining, .250-in. C x .838 in. L 1
5 39364 SPRING, Handle 1
6 39207 ADJUSTMENT PIN, Insulation Crimp 1