Tyco Electronics 90015 User manual

Instruction Sheet

408--1538

LOC B

1of 5

E2010 Tyco Electronics Corporation, Berwyn, PA

TE logo and Tyco Electronics are 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

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

25 AUG 10 Rev LHand Crimping Tools 90015 and 90016

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.

Tool Part

Number (Ref)

Back Side

of Tool

Insulation Crimping

Adjustment Pins

CERTI--CRIMP*

Tool Ratchet

Color Code

Marking

Crimping

Jaws

Terminal

Locator

Wire Size

Marking (Ref)

WIRE TERMINAL HAND TOOL

SIZE

(AWG)

INSULATION

DIA (mm [in.])

STRIP LENGTH

(mm [in.])

BASE PART

NUMBER

SHOULDER

LENGTH

SLEEVE

COLOR

PART

NUMBER

COLOR

CODE

CRIMP DOT

CODE

42927 Short

1.02--2.03

[

]

66059 Long Blue

Blue and

[.040--.080] 3.96 [.156] 42574 Short

90015

Yellow 1

24--22 42633 Long

ellow

26 2.03--2.92

[.080--.115] 66129 Long Black

1.52--2.54 42575 Short

20--18

[.060--.100] 4.75 [.187] 42634 Long White 90016

ean

Black 2

2.03--2.92 42637 Short

[.080--.115] 42646 Long Black

Figure 1

1. INTRODUCTION

Hand Crimping Tools 90015 and 90016 crimp the

PIDG* taper pin terminals (listed in Figure 1) onto

wire sizes 26 through 16 AWG. Read these

instructions thoroughly before crimping any terminals.

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Reasons for reissue of this instruction sheet are

provided in Section 7, REVISION SUMMARY.

NOTE

408- 1538

Hand Crimping Tools 90015 and 90016

Rev L2 of 5 Tyco Electronics Corporation

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 FULLY closed. See Figure 1.

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

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.

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.

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.

Squeezing the handles together too much will

engage the crimping jaws and deform the

terminal.

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.

Figure 2

Terminal Locator

Adjusted for Short

Shoulder Terminals

Back Side

of Tool

Shoulder of Short Shoulder

Terminal Against Locator

Tip of Terminal

Inserted Through

Hole in Locator

Stripped

Wire

Terminal Locator

Adjusted for Long

Shoulder Terminals

Back Side

of Tool

Tip of Terminal

Inserted Through

Hole in Locator

Shoulder of Long Shoulder

Terminal Against Locator

Stripped

Wire

CAUTION

NOTE

CAUTION

408- 1538

Hand Crimping Tools 90015 and 90016

3of 5Rev LTyco Electronics Corporation

Figure 3

Crimp Dot

Code (2 Dots)

3.18 mm [.125 in.]

Black Color

Coded Sleeve

Insulation

Barrel Sleeve

0.794 mm [.031 in.]

Blue Color

Coded Sleeve

Wire Barrel

Sleeve

Properly Crimped Terminals

Long Shoulder

Terminal

Short Shoulder

Terminal Crimp Dot

Code (1 Dot)

9. Remove the crimped terminal from the crimping

jaws and inspect the crimp. The crimp dot code on

the color coded sleeve will identify the hand tool

used. Make sure that the proper crimp dot code is

shown for the appropriate hand tool. Refer to

Figure 1. Refer to Figure 3 for a properly crimped

terminal. Check the insulation grip by referring to

Section 4, INSULATION CRIMPING

ADJUSTMENT.

Discard and replace any defective or damaged

terminal. DO NOT re--use a crimped terminal.

4. INSULATION CRIMPING ADJUSTMENT

Each hand tool has three insulation crimping

adjustment positions to adjust the wire insulation grip:

1--Tight, 2--Medium, and 3--Loose. To obtain the

desired insulation grip, proceed as follows:

1. Insert insulation crimping adjustment pins into

Position3asshowninFigure1.

2. Position terminal into crimping jaws as

described in Section 3, Step 5.

3. Insert an UNSTRIPPED wire just into the

insulation barrel sleeve.

4. Crimp the terminal using the procedure

described in Section 3, Step 8. Remove the

crimped terminal from the crimping jaws and check

the insulation support by bending the wire back

and forth once. The insulation barrel sleeve should

retain grip on the wire insulation. If the wire pulls

out, move the insulation crimping adjustment pins

to the next tighter position (Position 2) and proceed

to Step 5. If the wire does not pull out, the pins are

properly adjusted and the tool is ready for

crimping.

5. Perform another test crimp as described above.

Adjust pins, as necessary, until the desired

insulation grip is obtained. DO NOT use a tighter

setting than is required.

The pins must be located in the same adjustment

position.

5. MAINTENANCE AND INSPECTION PROCEDURE

It is recommended that a maintenance and inspection

program be performed periodically to ensure

dependable and uniform terminations. Frequency of

inspection depends on:

1. The care, amount of use, and handling of the

hand tool.

2. The presence of abnormal amounts of dust and

dirt.

3. The degree of operator skill.

4. Your own established standards.

The hand tool is inspected before being shipped from

the plant; however, Tyco Electronics recommends

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.

CAUTION

NOTE

408- 1538

Hand Crimping Tools 90015 and 90016

Rev L4 of 5 Tyco Electronics Corporation

4. When the tool is not in use, keep handles closed

to prevent objects from becoming lodged in the

crimping jaws. Store the tool in a clean, dry area.

5.2. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with SAE 20 motor oil as follows:

Tools used in daily production—lubricate daily

Tools used daily (occasional)—lubricate weekly

Tools 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.

5.3. Visual Inspection

1. Close tool handles until 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.

2. Inspect head assembly for worn, cracked, or

broken jaws. If damage is evident, return the tool

to Tyco Electronics for evaluation and repair. See

Section 6, REPLACEMENT AND REPAIR.

5.4. Gaging the Crimping Chamber

This inspection requires the use of plug gages

conforming to the dimensions provided in Figure 4.

Tyco Electronics does not manufacture or market

these gages. To gage the crimping chamber, proceed

as follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gages.

2. Close the tool handles until it is evident that the

jaws have bottomed; then hold in this position. Do

NOT force the jaws beyond initial contact.

3. Align the GO element with the appropriate

section of the crimping chamber. Push element

straight into the crimping chamber without using

force. The GO element must pass completely

through the crimping chamber as shown in

Figure 4.

4. Align the NO--GO element and try to insert it

straight into the same section of the crimping

chamber. The NO--GO element may start entry,

but must not pass completely through the crimping

chamber. See Figure 4.

If the crimping chamber conforms to the gage

inspection, the crimping chamber is considered

dimensionally correct, and should be lubricated with a

THIN coat of any good SAE 20 motor oil. If not, the

tool must be returned to Tyco Electronics for further

evaluation and repair. Refer to Section 6,

REPLACEMENT AND REPAIR.

For additional information regarding the use of plug

gages, refer to instruction sheet 408--7424.

Suggested Plug Gage Design for

Wire Barrel Section of Crimping Chamber

Dim.

NO--GO

Dim.

Jaw Closure

Configuration

GAGE ELEMENT DIMENSIONS (mm [in.])

HAND TOOL GO NO--GO

90015 1.600--1.607

[.0630--.0633]

1.747--1.750

[.0688--.0690]

90016 2.160--2.167

[.0850--.0853]

2.287--2.290

[.0900--.0902]

GO NO

6.35 mm [.250 in.]

Min Typ

Jaw Closure

Configuration

GO Dim. NO--GO Dim.

“W”

Suggested Plug Gage Design for

Insulation Barrel Section of Crimping Chamber

(Gage to be used at position 1 of insulation adjustment)

“W”

GAGE ELEMENT DIMENSIONS (mm [in.])

HAND TOOL GO NO--GO “W” (Width)

(Max)

90015

90016

0.889--0.897

[.0350--.0353]

1.394--1.397

[.0549--.0550]

2.36

[.093]

Figure 4

Crimping

Chamber

Element

NO--GO

Element

408- 1538

Hand Crimping Tools 90015 and 90016

5of 5Rev LTyco Electronics Corporation

5.5. CERTI- CRIMP Ratchet Inspection

The CERTI--CRIMP ratchet feature on the hand tools

should be checked to ensure that the ratchet does not

release prematurely, allowing the jaws to open before

they have fully bottomed. Obtain a 0.025--mm

[.001--in.] shim that is suitable for checking the

clearance between the bottoming surfaces of the

crimping jaws. Proceed as follows:

1. Select the maximum size wire for the tool and a

terminal.

2. Position the terminal and wire between the

crimping jaws, as described in Section 3,

CRIMPING PROCEDURE.

3. Hold the wire in place and squeeze the handles

until the CERTI--CRIMP ratchet releases. Hold the

handles in this position, maintaining just enough

tension to keep the jaws closed.

4. Check the clearance between the bottoming

surfaces of the crimping 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

Replaceable parts are listed in Figure 5. Parts other

than those listed in Figure 5 should be replaced by

Tyco Electronics to ensure quality and reliability of the

tool. Order replacement parts through your Tyco

Electronics 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 (38--35)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG, PA 17105--3608

For tool repair service, please contact a

representative at 1--800--526--5136.

7. REVISION SUMMARY

Since the previous release of this sheet, the TE logo

was applied.

22.22 mm [.875 in.]

76.2 mm [3.0

in.] (Closed)

279.4 mm [11.0 in.]

1 2 3 4 5

786

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QTY PER TOOL

121045--3 RING, External Crescent Retaining, .188 D Shaft 4

21--23619--6 PIN, Retaining, .187 D¢.521 L 2

321045--6 RING, External Crescent Retaining, .250 D Shaft 2

42--23620--9 PIN, Retaining, .250 D¢.838 L 1

939364 SPRING, Handle 1

539207 PIN, Insulation Crimping Adjustment 2

7125461--1 LOCATOR 1

83--21016--7 SCREW 1

Figure 5

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