90247-1

Instruction Sheet 408-- 7434 CERTI- CRIMP* Hand Crimping Tool 90247- 1 23 MAR 10 Rev B 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. Insulation Crimp Adjustment Lever F AMP Fixed Dies (Crimpers) Contact Support 90247---1 Movable Dies (Anvils) Front of Tool (Contact Side) The FRONT of the tool, into which the contact is inserted, has the tool number marked on it. The BACK of the tool, into which the wire is inserted, has the applicable wire size range marked above each crimping chamber. The contact support prevents the contact from bending during the crimping operation. The insulation crimp adjustment lever is used to control the crimp height of the contact insulation barrel when crimped. The locator/wire stop positions the contact between the dies before crimping and limits the insertion distance of the stripped wire into the contact. In use, it rests in the locator slot of the contact. The ratchet assures full crimping of the contact. Once engaged, the ratchet will not release until the handles have been FULLY closed. The dies bottom before the ratchet releases. This feature ensures maximum electrical and tensile performance of the crimp. DO NOT re--adjust the ratchet. CAUTION ! Ratchet 3. CRIMPING PROCEDURE Figure 1 1. INTRODUCTION CERTI--CRIMP Hand Crimping Tool 90247--1 (shown in Figure 1) is used to crimp MATE--N--LOK* .140 pin and socket contacts listed in Figure 2 onto wire sizes 20 through 14 AWG with an insulation diameter range of 2.54 through 4.56 mm [.100 through .180 in.]. Read these instructions thoroughly before using the tool. NOTE i Make sure that the specified wire size and insulation diameter is compatible with the contact and tool. Strip the wire to the length indicated in Figure 2—DO NOT cut or nick the wire strands. Typical MATE- N- LOCK .140 Contact Wire Barrel Socket Stabilizer Locator Slot Mating End Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY. The tool features fixed dies (crimpers), movable dies (anvils), contact support, locator/insulation stop, insulation crimp adjustment lever, and ratchet. When mated, the dies form two crimping chambers. Insulation Barrel Pin Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale. 2. DESCRIPTION 6.35 [2.50] Wire Strip Length Note: Not to Scale WIRE CONTACT SIZE (AWG) INSULATION DIAMETER 20 14 20--14 2.54--4.57 [.100--.180] TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2010 Tyco Electronics Corporation, Berwyn, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products names, logos, or company names might be trademarks of their respective owners. TYPE STRIP FORM LOOSE PIECE Pin 61627--[ ] 350389--[ ] Socket 61626--[ ] 350388--[ ] Figure 2 This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 4 LOC B 408-- 7434 CERTI-- CRIMP Hand Crimping Tool 90247-- 1 If using a strip--form contact, the cutoff tabs MUST meet the dimension requirement stated in Application Specification 114--1007 or the customer drawing for the product. NOTE i Proceed as follows: Crimp Inspection Wire Barrel Seam Must Be Completely Closed With No Loose Wire Strands 1. Hold the tool so the BACK of the tool (wire side) is facing you. Wire Insulation Must Not Enter Wire Barrel 2. Ensure that the tool ratchet is released by squeezing the tool handles and allowing them to open FULLY. End of Wire Must Be Even With or Protrude Slightly from End of Wire Barrel 3. Insert the contact, mating end first, into the appropriate crimping chamber from the BACK of the tool. Position the contact between the dies so that the locator/insulation stop enters the contact locator slot. See Figure 3. Figure 4 NOTE i Crimping Contact Back of Tool (Wire Side) Contact Support Locator/Insulation Stop in Contact Locator Slot For detailed crimp inspection requirements, refer to Application Specification 114--1007. 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 wire 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 wire insulation firmly without cutting into it. 5. MAINTENANCE AND INSPECTION The tool is inspected before shipment. The tool should be inspected immediately upon arrival at your facility to ensure that the tool was not damaged during shipment. Stripped Wire Figure 3 5.1. Daily Maintenance 4. Holding the contact in position, squeeze the tool handles together until the dies close just enough to hold the contact in place. DO NOT deform contact wire barrel or insulation barrel. 5. Insert a properly stripped wire into the contact wire barrel until the wire insulation butts against the locator/insulation stop. 6. Holding the wire in place, squeeze the tool handles together until the ratchet releases. Allow the tool handles to open FULLY. 7. Remove the crimped contact from the tool, and inspect the crimp according to Figure 4. 2 of 4 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 secured with the proper retaining rings. If foreign matter cannot be removed easily, or if the proper replacement parts are not available, refer to Section 6, REPLACEMENT AND REPAIR, for information on obtaining further evaluation and repair. Make certain all pivot points and bearing surfaces are protected with a THIN coat of any good SAE 20 motor oil. Do NOT oil excessively. When 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. Tyco Electronics Corporation Rev B 408-- 7434 CERTI-- CRIMP Hand Crimping Tool 90247-- 1 5.2. Periodic Inspection Regular inspections should be performed by quality control personnel. A record of scheduled inspections should remain with the tool and/or be supplied to 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: Position Point on Center of Wire Barrel Opposite Seam 2. Make certain all retaining pins are in place and secured with retaining rings. If replacements are necessary, refer to parts listed in Section 6, REPLACEMENT AND REPAIR. CAUTION ! DO NOT remove the retaining pins as permanent damage to the tool may result. 3. Close the tool handles until the ratchet releases, then allow the tool handles to open freely. If handles do not open quickly and fully, the spring is defective and must be replaced (see Section 6). 4. Inspect the head assembly, with special emphasis on checking for worn, cracked, or broken dies. If damage to any part of the head assembly is evident, refer to Section 6 for information on obtaining customer repair service. B. Crimp Height Inspection Crimp Height Modified Anvil WIRE SIZE (AWG) (Max) CRIMP HEIGHT DIMENSION (+0.08 [+.003]) 18 1.40 [.055] 14 1.68 [.066] A. Visual Inspection 1. Remove all lubrication and accumulated film by immersing the tool (handles partially closed) in a suitable commercial degreaser that will not affect paint or plastic material. Spindle Figure 5 For additional information concerning the use of the crimp height comparator, refer to 408-- 7424. C. Ratchet Inspection Obtain a 0.0254 [.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 maximum size wire for the tool. 2. Position the contact and wire between the dies, according to Section 3, CRIMPING PROCEDURE. Holding the wire in place, squeeze the tool handles together until the ratchet releases. Hold the tool handles in this position, maintaining just enough pressure to keep the dies closed. 3. Check the clearance between the bottoming surfaces of the dies. If the clearance is 0.0254 [.001] or less, the ratchet is satisfactory. If clearance exceeds 0.0254 [.001] the ratchet is out of adjustment and must be repaired (see Section 6, REPLACEMENT AND REPAIR). This inspection requires the use of a micrometer with a modified anvil as shown in Figure 5. The modified micrometer (Crimp Height Comparator RS--1019--5LP) is recommended. 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. Proceed as follows: 6. REPLACEMENT AND REPAIR 1. Select a contact and maximum size wire for the crimping chamber. 2. Refer to Section 3, CRIMPING PROCEDURE, and crimp the contact 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, the tool is considered dimensionally correct. If not, refer to Section 6 for information on obtaining evaluation and repair. SAE is a trademark of SAE International Corporation. Rev B Customer--replaceable parts are listed in Figure 6. A complete inventory should be stocked and controlled to prevent lost time when replacement of parts is necessary. Parts other than those listed should be replaced by Tyco Electronics to ensure quality and reliability. Order replacement parts through your 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 Tyco Electronics Corporation 3 of 4 408-- 7434 CERTI-- CRIMP Hand Crimping Tool 90247-- 1 CAUTION: Do NOT remove retaining pins as permanent damage to the tool may result. 1 Retaining Pin (Ref) 2 90247---1 Retaining Pin (Ref) 63.5 [2.5] (Closed) 301.75 [11.88] 19.05 [.75] Weight: 509 g [1 lb, 4 oz] REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY PER TOOL 1 21045--3 RING, Retaining 4 2 21045--9 RING, Retaining 2 Figure 6 For customer repair service, call 1--800--526-- 5136. 7. REVISION SUMMARY Revisions to this instruction sheet include: S Updated instruction sheet to corporate requirements 4 of 4 Tyco Electronics Corporation Rev B