Tyco Electronics 90301-2 Bedienungsanleitung

Instruction Sheet

408-7909

LOC B

of 4

2008 Tyco Electronics Corporation, Harrisburg, PA

All International ights eserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTE 1-800-722-1111

P ODUCT INFO MATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and egional Customer Service,

visit our website at

www.tycoelectronics.com

25 NOV 08 ev C

Hand Crimping Tool 90301-2

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresult fromtheprolongeduseofmanuallypoweredhand tools.Handtoolsareintendedforoccasional useandlowvolume

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

Figure 1

Insulation Crimp

Adjustment Lever

Front of Tool

(Contact Side)

Anvils

Crimpers

Contact

Support

90301-2

CE TI-C IM

Hand Crimpin

Tool atchet

Control

1. INTRODUCTION

AMP* Hand Crimping Tool 90301–2 is designed to

crimp the Tandem Spring loose piece (LP) contacts

listed in Figure 1. Read these instructions thoroughly

before using the tool.

All dimensions in this document are in millimeters

[ ith inches in brackets]. Illustrations are not

dra n 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, an inner and

outer contact support, and a CERTI–CRIMP hand

crimping tool ratchet control.

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 inner and outer contact supports prevent the

contact from bending during the crimping operation.

The CERTI–CRIMP ratchet ensures full crimping of

the contact. Once engaged, the ratchet will not

release until the tool handles have been fully closed.

The crimping dies bottom before the ratchet

releases. This is a design feature that ensures

maximum electrical and tensile performance of

the crimp. Do NOT re-adjust the ratchet.

Insulation Barrel

Locator Slot

Wire Barrel

Strip Length

3.56 [.140]

WIRE CONTACT NUMBER CRIMP

SECTION

SI E

(AWG)

NSUL

DIA LOOSE

PIECE STRIP

SECTION

(Wire Size

Marking)

530553-5 530553-2,

-7

-4, -6

26 to 22 0.91 - 1.42

[.036-.056] 531216-2,

-4 531216-1,

-3 26-22

531224-7 531224-6

32 to 28 0.64 - 1.37

[.025-.054] 530901-3,

-5, -7 530901-2,

-4, -6 32-28

Figure 2

NOTE

CAUTION

408-7909

Hand Crimping Tool 90301-2

Rev

of 4 Tyco Electronics Corporation

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 Maintenan e

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.

Figure 3

26-22

32-28

Stripped Wire

Locator/Insulation

Stop

Back of Tool

(Wire Side) Outer Contact Support

Inner Contact Support

Insulation

Anvil

Locator Slot

(In Contact)

Insulation

Cri per

Cri p Section

Wire Size Marking

408-7909

Hand Crimping Tool 90301-2

of 4Rev

Tyco Electronics Corporation

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

This inspection requires the use of micrometer, with a

modified anvil, as shown in Figure 4. The Crimp

Height Comparator RS–1019–5LP is recommended

and is available from:

Shearer Industrial Supply Co.

20 North Penn Street

York, PA 17401–1014

VALCO

1410 Stonewood Drive

Bethlehem, PA 18017–3527

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).

For additional information concerning the use of the

crimp height comparator, refer to Instruction Sheet

408–7424.

Position Point on

Center of Wire Barrel

Opposite Seam

Mo ifie

Anvil

A"

+0.05

[+.002]

CONTACT

N MBER (LP) WIRE SIZE

AWG (Max.)

CRIMP SECT

(Wire Size

Marking)

CRIMP

HEIGHT

DIM. A"

530553-5,-7

531216-2,-4

531224-7 22 26-22 0.76 [.030]

530901-3,-5,-7 28 32-28 0.56 [.022]

Figure 4

C. CERTI-CRIMP Hand Crimping Tool Ratchet Control

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 CERTI–CRIMP 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.

408-7909

Hand Crimping Tool 90301-2

Rev

o 4 Tyco Electronics Corporation

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 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

P.O. 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. RE ISION SUMMARY

Since the previous release, the logo was updated.

19.0 [.75]

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

WEIGHT:

567 g [1 lb. 4 oz.]

AMP

90301-2

301.8 [11.88]

63.5 [2.50]

(Closed)

CAUTION

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QUANTITY PER TOOL

1 21045-3 Ring, Retaining 4

2 21045-6 Ring, Retaining 2

Figure 5

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