Instruction Sheet
Hand Crimping Tool 90274-2
408-7594
26 SEP 11 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
Front of Tool
(Contact Side)
Contact Support
Crimpers
Anvils
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 support prevents the contact from
bending during the crimping operation.
The contact locator/insulation stop has two functions.
First, it is used to position the contact between the
crimping dies, and second, it aids in locating the wire
in the contact. In use, it rests in the contact locator
slot. See Figures 2 and 3.
The ratchet ensures full crimping of the contact. Once
engaged, the ratchet will not release until the tool
handles have been fully closed.
Wire Barrel
Insulation Barrel
Ratchet
Locator Slot
Wire Strip Length
4.34 [.171]
Figure 1
1. INTRODUCTION
WIRE
Hand Crimping Tool 90274-2 is designed to crimp the
AMPMODU* MOD I loose-piece (LP) contacts listed in
Figure 2. Read these instructions thoroughly before
crimping any contacts.
NOTE
i
All dimensions on 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.
SIZE
(AWG)
INSUL
DIA
22 to 20
1.30 to 2.29
[.051 to .090]
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
18
2. DESCRIPTION (Figures 1 and 3)
This tool features two fixed dies (crimpers), two
movable dies (anvils), an insulation crimp adjustment
lever, a contact support, a contact locator/insulation
stop, and a tool ratchet.
© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
CONTACT NO.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
LP
STRIP
87026
87023
87027
87024
102103
102099
102104
102100
87026
87023
87027
87024
102103
102099
102104
102100
CRIMP
SECTION
(Wire Size
Marking)
22-20
18
Figure 2
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.
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LOC B
408-7594
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.
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
4. Position the contact in the crimpers so that the
locator/insulation stop enters the locator slot of 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.
5.1. 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.
Back of Tool
(Wire Side)
Locator / Insulation Stop
Crimp Section
Wire Size Marking
Contact Support
Insulation Crimper
Locator Slot
in Contact
Stripped Wire
Insulation Anvil
Figure 3
Rev B
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408-7594
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 inspections 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 head assembly, 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
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.
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.
Rev B
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).
Position Point on
Center of Wire
Barrel Opposite
Seam
Modified
Anvil
CONTACT
NUMBER
(LP)
87026
87027
102103
102104
“A”
±0.05
[±.002]
WIRE SIZE
AWG (Max)
CRIMP SECT
(Wire Size
Marking)
CRIMP
HEIGHT DIM.
“A”
20
22-20
0.84 [.033]
18
18
1.07 [.042]
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 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 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.
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408-7594
6. REPLACEMENT AND REPAIR
7. REVISION SUMMARY
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
representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 1-717-986-7605, or
write to:
Since the previous version of this document, the
following changes were made:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
• Updated crimp height comparator sourcing
information in Paragraph 5.2.B
• Corrected trademark references to tool and
ratchet throughout.
• Updated contact information in Section 6.
• Updated document to corporate requirements.
For customer repair service, call 1-800-526-5136.
63.5 [2.50]
(Closed)
2
1
19.0 [.75]
301.8 [11.88]
WEIGHT: 567g [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
QTY PER TOOL
1
21045-3
Ring, Retaining
4
2
21045-9
Ring, Retaining
2
Figure 5
Rev B
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