Tyco Electronics 90430-1 Bedienungsanleitung

Instruction heet

408-9375

LOC B

of 4

2007 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

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

TOOLING A I TANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer ervice,

visit our website at

www.tycoelectronics.com

15 MAY 07 Rev D

H nd Crimping Tool 90430-1

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume

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

Figure 1

AMP

90430–1

Insulation

Adjustment

Lever

FRONT of TOOL

(Contact ide)

Contact upport

Crimpers

Tool Number

Anvils

CERTI-CRIMP*

Ratchet

1. INTRODUCTION

This instruction sheet covers the use of Hand

Crimping Tool 90430–1 which is designed to crimp

High Density 22 DF loose–piece contacts shown in

Figure 2. Read these instructions thoroughly before

using the tool.

Reasons for reissue are provided in Section 6,

REVISION SUMMARY.

All di ensions on this docu ent are in etric

units [with U.S. custo ary units in brackets].

Figures and illustrations are for identification only

and are not drawn to scale.

2. DESCRIPTION

The FRONT OF TOOL, into which the contact is

inserted, has the tool number marked on it (refer to

Figure 1). The BACK OF TOOL (wire side) has the

wire size marked above each crimp section. The tool

features two fixed dies (crimpers), two movable dies

(anvils), two crimp sections with applicable wire–size

markings, a contact support, a locator/wire stop, and

a CERTI–CRIMP ratchet.

The insulation adjustment lever is used to control the

crimp height of the contact insulation barrel. Refer to

Paragraph 4.6, Insulation Crimp Adjustment.

The CERTI–CRIMP ratchet assures full crimping of

the contact. Once engaged, the ratchet will not

release until the handles have FULLY closed.

The cri ping dies botto before the

CERTI-CRIMP ratchet releases. This design

feature assures axi u electrical and tensile

perfor ance of the cri p. Do NOT re-adjust the

ratchet.

The locator/wire stop has two functions. First, it

positions the contact between the crimping dies, and

second, it aids in locating the wire in the contact. In

use, it rests in the locator slot. See Figures 2 and 3.

The contact support prevents the contact from

bending during the crimping procedure.

3. CRIMPING PROCEDURE

Refer to the chart in Figure 2 and select wire of the

specified size and insulation diameter. Strip the wire

to the length indicated. Do NOT cut or nick the wire

strands.

Insulation Barrel

Wire Barrel ocket Contact

(Ref)

houlder of

Contact

Locator

lot

Wire trip Length 4.06 [.160]

WIRE

CONTACT

CRIMP SECTION WIRE

SIZE INSUL DIA

CONTACT

SIZE MARKING

28-26 0.76-1.02 High Density 26-28

24-22 [.030-.040]

22 DF 22-24

For applicable contact part numbers, see Catalog 82068.

Figure 2

NOTE

CAUTION

408-9375

Hand Cr mp ng Tool 90430-1

Rev

f4 Tyc Electr nics C rp rati n

Figure 3

22–24

26–28

Insert C ntact

Int Fr nt f T l

Insulati n Adjustment Lever

Crimp Secti n

Wire Size

Marking

Stripped

Wire

Back f T l

(Wire Side)

L cat r/

Wire St p

On the BACK of the tool, identify the appropriate

crimp section (according to the wire size markings).

Refer to Figure 3 and proceed as follows:

1. Hold tool so BACK (wire side) is facing you.

2. Make sure ratchet is released by squeezing the

tool handles and allowing them to open FULLY.

3. Insert contact (insulation barrel first) into

FRONT of appropriate crimp section. Position the

contact in crimp section so that locator/wire stop

butts against the shoulder of the contact as shown

in Figure 4.

4. Hold contact in this position and squeeze tool

handles together until insulation anvil starts entry

into insulation crimper. Do NOT deform insulation

barrel or wire barrel.

5. Insert a properly stripped wire into wire barrel of

contact until it stops.

6. Holding wire in place, squeeze tool handles until

ratchet releases.

7. Allow tool handles to open FULLY and remove

crimped contact from tool.

4. MAINTENANCE AND INSPECTION PROCEDURE

Tyco Electronics recommends 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;

however, Tyco Electronics recommends that the tool

be inspected immediately upon its arrival at your

facility to ensure that the tool has not been damaged

during shipment.

Due to the precision design, it is important that no

parts of these tools be interchanged except those

replacement parts listed in Figure 6.

4.1. Da ly Ma ntenance

1. Remove dust, moisture, and other contaminants

with a clean brush, or a soft, lint–free cloth. Do

NOT use objects that could damage the tool.

2. Make certain that the retaining pins are in place

and that they are secured with retaining rings.

Figure 4

Insulati n Crimp

Adjustment Lever

Back f T l

(Wire Side)

L cat r/

Wire St p

L cat r/Wire St p

Must Rest Against

Sh ulders as Sh wn

Crimping

Dies

Insert

C ntact

int Fr nt

f T l

3. All pins, pivot points, and bearing surfaces

should be protected with a thin coat of any good

SAE No. 20 motor oil. Do not oil excessively.

408-9375

Hand Crimping ool 90430-1

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Tyco Electron cs Corporat on

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. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with SAE No. 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.

4.3. Periodic Inspection

1. Hand tool should be immersed (handles partially

closed) in a reliable commercial degreasing

compound to remove accumulated dirt, grease,

and foreign matter.

2. 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.

3. Inspect head assembly for worn, cracked, or

broken dies. If damage is evident, return the tool

for evaluation and repair. See Section 5,

REPLACEMENT AND REPAIR.

4.4. Crimp Height Inspection

This inspection requires the use of micrometer with a

modified anvil as shown in Figure 5. Tyco Electronics

recommends use of the modified micrometer (Crimp

Height Comparator RS–1019–5LP) which can be

purchased from:

ShearerIndustrialSupplyCo.

717–767–7575 or VALCO

610–691–3205

Proceed as follows:

1. Refer to the chart in Figure 5 and select a

contact and a wire (maximum size) for each crimp

section listed in the chart.

2. Refer to Section 3, CRIMPING PROCEDURE,

and crimp the contact(s) accordingly.

3. Using a crimp height comparator, measure wire

barrel crimp height as shown in Figure 5. 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 5, REPLACEMENT AND REPAIR).

A"

+0.05 [+.002]

CON AC WIRE SIZE

AWG (MAX)

CRIMP SEC

WIRE SIZE

MARKING DIM. A"

H gh Dens ty 26 26-28 0.69 [.027]

22 DF 22 22-24 0.79 [.031]

Figure 5

For additional information concerning the use of the

crimp height comparator, refer to Instruction Sheet

408–7424.

4.5. CER I-CRIMP Ratchet Inspection

The CERTI–CRIMP ratchet feature on 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–mm [.001–in.] shim that is suitable for checking

the clearance between the bottoming surfaces of the

crimping dies. Proceed as follows:

1. Select the maximum size wire and strip it

according to dimensions listed in Figure 2.

2. Select contact and crimp section corresponding

to the selected wire size (refer to Figure 2).

3. Position the contact and wire between the

crimping dies, as described in Section 3,

CRIMPING PROCEDURE.

4. 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 dies closed.

5. Check the clearance between the bottoming

surfaces of the crimping dies. 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 5, REPLACEMENT AND

REPAIR.

4.6. Insulation Crimp Adjustment

The insulation barrel crimp height is controlled by the

insulation adjustment lever. To determine the proper

setting, test crimp a contact using the setting which

approximates the insulation size (1–small, 2–medium,

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.

408-9375

H nd Crimping Tool 90430-1

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of 4 Tyco El ctronics Corporation

5. REPLACEMENT AND REPAIR

Replacement parts are listed in Figure 6. Parts other

than those listed in Figure 6 should be replaced 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.

For tool repair service or CERTI–CRIMP ratchet

adjustment, return the tool, with a written description

of the problem to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105–3608

6. REVISION SUMMARY

Updated document to corporate requirements

Changed Dimension “A” tolerance in Figure 5

12302

[11.9]

19.1 [.75]

63.5 [2.50]

(Clos d)

ITEM PART NUMBER DESCRIPTION QTY

1 21045-3 RING, R taining 4

2 21045-9 RING, R taining 2

Figure 6

AMP

90430-1

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