TE Connectivity 90382- 2 User manual

Instruction Sheet

408--6561

LOC B

1of 4

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company

TE logo is a trademark.

*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.te.com

16 Mar 11 Rev DHand Crimping Tool 90382- 2

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

Front Side

of Tool

Contact

Locator

Crimpers

Anvils

Ratchet

1. INTRODUCTION

Hand Crimping Tool 90382--2 (shown in

Figure 1) is designed to crimp the Type XII Contacts

listed in Figure 2. Read these instructions thoroughly

before using the tool.

Dimensions are in millimeters [followed by

inch equivalents in brackets]. Figures are for

identification only and are not drawn to scale.

Reasons for re--issue can be found in Section 6,

REVISION SUMMARY.

2. DESCRIPTION

The hand tool features two fixed crimping dies

(crimpers) and two movable crimping dies (anvils), a

contact locator, a wire stop, and a CERTI--CRIMP*

Hand Crimping Tool Ratchet Control. See Figure 1.

The contact locator positions the contact between the

crimping dies. In use, the contact locator rests in the

locator slot of the contact.

Thewirestopaidsinlocatingthewireinthecontact.

In use, the wire stop rests in the wire stop slot of the

contact.

The ratchet ensures full crimping of the contact. Once

engaged, the ratchet will not release until the handles

have been fully closed.

The crimping dies bottom before the ratchet

releases. This design feature ensures maximum

electrical and tensile performance of the crimp.

Do NOT re--adjust the ratchet.

Wire

Stop Slot

Pin Contact

Insulation

Barrel

Wire

Barrel

Locator

Slot

Insulation

Barrel

Locator

Slot

Wire

Barrel

Socket

Contact

Wire

Stop Slot

Wire

Strip

Length

WIRE CONTACT

SIZE

(AWG)

INSUL

DIA

STRIP

LENGTH TYPE LOOSE

PIECE STRIP

66261 66255

16 to 12 3.68--4.19

[

.145--.165

]

6.35

[

.25

]

n66262 66256

[

]

[

]

Socket 66746 66252

Figure 2

NOTE

CAUTION

408- 6561

Rev D2 of 4

Figure 3

Front Side

of Tool

(Wire Side)

Stripped

Wire

Contact

Locator

Wire Slot in Locator

Insulation Barrel

Locator Slot

in Contact

Wire Slot

in Contact

Wire Stop

3. CRIMPING PROCEDURE

Refer to Figure 2 and select the appropriate contact

and wire size for the hand tool. The wire size and

insulation diameter must be within the specified range

for the contact. Strip the wire to the length shown in

Figure 2. Do NOT nick or cut the wire strands.

1. Open crimping dies by squeezing the tool

handles together until the ratchet releases.

2. Insert the contact insulation barrel into the

crimping chamber on the anvil crimping die from

the BACK side of tool. Position contact so that the

contact locator enters the locator slot in the

contact. See Figure 3.

3. Holding contact in position, squeeze tool

handles together just enough to hold the contact in

the crimping dies. Do NOT deform the insulation

barrel or wire barrel.

4. Insert stripped wire through wire slot in contact

locator and into wire barrel of contact until the wire

butts against the wire stop.

5. Holding wire in place, squeeze tool handles

together until ratchet releases.

6. Allow tool handles to open FULLY and remove

crimped contact from tool.

4. MAINTENANCE AND INSPECTION

A periodic maintenance and inspection program is

recommended to ensure dependable and uniform

terminations. Though recommendations call for at

least one inspection a month, frequency of inspection

depends on:

SThe care, amount of use, and handling of the

hand tool,

SThe presence of abnormal amounts of dust

and dirt,

SThe degree of operator skill, and

SYour own established standards.

Although the hand tool is inspected before being

shipped, it should be inspected immediately upon

arrival at your facility to ensure that it has not been

damaged during shipment.

4.1. 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.

408- 6561

3of 4Rev D

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

to prevent objects from becoming lodged in the

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

4.2. 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 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. See Section 5, REPLACEMENT AND

REPAIR.

2. Inspect head assembly for worn, cracked, or

broken dies. If damage is evident, return the tool to

TE for evaluation and repair. See Section 5,

REPLACEMENT AND REPAIR.

C. Crimp Height Inspection

This inspection requires the use of a micrometer with

a modified anvil. TE does not manufacture or market

these gages, however TE recommends a modified

micrometer (Crimp Height Comparator

RS--1019--5LP).

Proceed as follows:

1. Select a contact and wire for the crimping

chamber.

2. Refer to Section 3, CRIMPING PROCEDURE,

and crimp the contact accordingly.

3. Using the crimp height comparator, 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, the tool

must be returned for evaluation and repair. See

Section 5, REPLACEMENT AND REPAIR.

For additional information concerning the use of the

crimp height comparator, refer to instruction sheet

408--7424.

Figure 4

Position Point

on Center of

Wire Barrel

Opposite

Seam

Modified

Anvil Crimp Height

2.39+0.08

[.094+.003]

D. Ratchet Inspection

The ratchet feature on these hand tools should be

checked to ensure that the ratchet does not release

prematurely, allowing the crimping dies to open before

they have fully bottomed. Obtain a 0.025 [.001] shim

that is suitable for checking the clearance between

the bottoming surfaces of the crimping dies. Proceed

as follows:

1. Select a contact and wire for the tool.

2. Position the contact and wire between the

crimping dies, as described in Section 3,

CRIMPING PROCEDURE.

3. Holding wire in place, squeeze the handles 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

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

of adjustment and must be repaired. See Section

5, REPLACEMENT AND REPAIR.

408- 6561

Rev D4 of 4

82.6

[3.25]

(Closed)

25.4

[1.00]

311.2

[12.25]

3 4

1 2

Weight: 936g[2lb,1oz]

CUSTOMER REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QTY PER TOOL

121045--3 RING, Retaining 4

2300388 PIN, Retaining 2

321045--6 RING, Retaining 2

4300389 PIN, Retaining 1

Figure 5

5. 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. Parts other than those listed

should be replaced by TE to ensure quality and

reliability of the tool. 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 (38--35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105--3608

Tools may also be returned for evaluation and repair.

For tool repair service, contact a TE Representative

at: 1--800--526--5136.

Contacts are not repairable once a termination

has been made. Any defective contact should be

removed and replaced with a new one.

6. REVISION SUMMARY

The following changes were made since the previous

release of this sheet:

SUpdated document to corporate requirements.

CAUTION

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