90075-1

Instruction Sheet   Hand Crimping Tool 90075-1 Front of Tool (Contact Side) Crimpers 408-7092 23 MAR 12 Rev C The ratchet ensures full crimping of the terminal. Once engaged, the ratchet will not release until the tool handles have been fully closed. CAUTION ! Anvils 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. 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. Spade Terminal Wire Barrel Ratchet Insulation Barrel Ring Tongue Terminal 1. INTRODUCTION WIRE Hand Crimping Tool 90075-1 is designed to crimp the spade and ring tongue terminals listed in Figure 2. Read these instructions thoroughly before crimping any contacts. NOTE i All dimensions in this document are in metric units [with U.S. customary units in brackets]. Figures and illustrations are for identification only and are not drawn to scale. Reasons for reissue of this instruction sheet are provided in Section 6, REVISION SUMMARY. 2. DESCRIPTION (Figure 1) This tool features two fixed dies (crimpers), two movable dies (anvils), a terminal locator/insulation stop, and a ratchet. The terminal locator/insulation stop positions the terminal between the crimping dies. In addition, the locator/insulation stop aids in locating the wire in the terminal. In use, it rests in the terminal locator slot. See Figures 2 and 3. © 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company All Rights Reserved *Trademark Wire Strip Length 4.75 [.187] Locator Slot Figure 1 QTY SIZE (AWG) 1 24 1 20 2 26 2 22 INSULATION DIAMETER CRIMP SECT (Wire Size Marking) 1.22 to 1.98 [.048 to .078] TERMINAL PART NO. 24 - 20 2 - 26 2 - 22 60445 60500 60501 60553 60555 Figure 2 Select an applicable terminal 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 terminal (insulation barrel first) into the front of the appropriate crimp section. See Figure 3. 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 TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 1 of 4 408-7092 4. Position the terminal in the crimpers so that the locator/insulation stop enters the locator slot in the terminal. use, keep the handles closed to prevent objects from becoming lodged between the dies, and store the tool in a clean, dry area. 5. Hold the terminal 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. 4.2. Periodic Inspection 6. Insert a properly-stripped wire or wires through the wire slot of the locator and into the wire barrel of the terminal until the wire insulation butts against the locator/insulation stop. 7. While holding the wire(s) in place, squeeze the tool handles together until the ratchet releases. 8. Allow the tool handles to open fully and remove the crimped terminal. 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. 4. MAINTENANCE/INSPECTION 4.1. Daily Maintenance 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. 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 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 5, REPLACEMENT AND REPAIR). Back of Tool (Wire Side) Locator / Insulation Stop Crimp Section Wire Size Marking Insulation Crimper Locator Slot in Contact Stripped Wire Insulation Anvil Figure 3 Rev C 2 of 4 408-7092 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 5, REPLACEMENT AND REPAIR). B. Crimp Height Inspection Crimp height inspection is performed through the use of a micrometer with a modified anvil, commonly referred to as a crimp height comparator.  TE does not market crimp height comparators. Refer to Instruction Sheet 408-7424 for detailed information on obtaining and using a crimp height comparator. Refer to Figure 4 and proceed as follows: 1. Refer to the chart in Figure 4 and select a terminal and a wire (maximum size) for each crimp section. 2. Refer to Section 3, CRIMPING PROCEDURE, and crimp the terminal(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 5, REPLACEMENT AND REPAIR). Position Point on Center of Wire Barrel Opposite Seam 2. Position the terminal 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. 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. Order replacement parts through your  TE Connectivity 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 (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 For customer repair service, call 1-800-526-5136. 6. REVISION SUMMARY Since the previous version of this document, the following changes were made: Modified Anvil “A” ±0.05 [±.002] TERMINAL NUMBER WIRE SIZE AWG (Max) CRIMP SECT (Wire Size Marking) 60445 60500 60501 60553 60556 20 24 - 20 (2) 22 2 - 26 2 - 22 CRIMP HEIGHT DIM. “A” • Removed logos from graphics. • Removed trademark references to ratchet. • Updated crimp height inspection and comparator sourcing information. • Updated logo and format to corporate requirements. 0.94 [.037] Figure 4 C. Ratchet Inspection 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 terminal and maximum size wire for the hand tool. Rev C 3 of 4 408-7092 63.5 [2.50] (Closed) 1 19.0 [.75] 301.8 [11.88] WEIGHT: 567 g [1 lb 4 oz] CAUTION Do not remove the retaining pins or permanent damage to the tool may result. ! REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QUANTITY PER TOOL 1 21045-3 Ring, Retaining 4 Figure 5 Rev C 4 of 4