TE Connectivity 90084 User manual

Instruction Sheet
408--7114
1of 4
.2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company
All Rights Reserved
*Trademark
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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
21 MAR 12 Rev BHand Crimping Tool 90084
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.
Figure 1
Crimper
Jaws
Anvil
Jaws
Ratchet
1. INTRODUCTION
Hand Crimping Tool 90084 is designed to crimp the
loose piece (LP) Tab Receptacle terminals listed in
Figure 2. Read these instructions thoroughly before
crimping any terminals.
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
This tool features two crimper jaws, two anvil jaws, a
terminal locator, and a ratchet.
The terminal locator positions the terminal between
the crimping jaws.
The ratchet ensures full crimping of the terminal.
Once engaged, the ratchet will not release until the
tool handles have been fully closed.
The crimping jaws 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.
Wire Strip Length
3.57 [.141]
Insulation
Barrel Wire
Barrel
Tab Receptacle
WIRE TERMINAL NO.
SIZE (AWG) INSUL DIA LP STRIP
60560 60477
60561 60436
24 to 20 1.02 to 2.03
[
0
4
0
t
o
0
8
0
]
60578 60524
[
.
0
4
0
t
o
.
0
8
0
]
61403 60524
60751 60530
Figure 2
NOTE
i
CAUTION
!

408- 7114
Rev B2 of 4
Select an applicable terminal and proceed as follows:
1. Hold the tool so that the front is facing you.
2. Make sure that the ratchet is released. Squeeze
the tool handles together and allow them to open
fully.
3. Insert the terminal into the locator. Make sure
terminal insulation barrel and wire barrel are facing
tool crimper jaws and tab receptacle is bottomed in
locator.SeeFigure3.
4. Hold the terminal in this position and squeeze
the tool handles together until the crimping jaws
close just enough to retain the terminal. Do NOT
deform the insulation barrel or wire barrel.
5. Insert a properly--stripped wire through the
terminal insulation barrel and into the wire barrel.
End of wire must be flush with end of wire barrel.
6. While holding the wire in place, squeeze the tool
handles together until the ratchet releases.
7. Allow the tool handles to open fully and remove
the crimped terminal.
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
use, keep the handles closed to prevent objects from
becoming lodged between the jaws, and store the tool
in a clean, dry area.
4.2. 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:
Figure 3
Locator
Receptacle Bottomed
in Locator
Insulation
Barrel
Stripped
Wire
Back of Tool
(Wire Side)
Crimper
Jaws
Wire
Barrel

408- 7114
3of 4Rev B
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 5,
REPLACEMENT AND REPAIR).
4. Inspect the tool, with special emphasis on
checking for worn, cracked, or broken crimping
jaws. 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
This inspection requires the use of a 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
or
Proceed as follows:
1. Refer to the chart in Figure 4 and select a
terminal and a wire (maximum size) for the hand
tool.
Position Point on
Center of Wire
Barrel Opposite
Seam
Modified
Anvil
“A”
+0.05 [+.002]
TERMINAL
NUMBER
WIRE SIZE
AWG (Max.)
CRIMP HEIGHT
DIM. “A”
60560 61403
60561 60751
60578
20 0.81 [.032]
Figure 4
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the terminal 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).
For additional information concerning the use of the
crimp height comparator, refer to Instruction Sheet
408--7424.
C. Ratchet Inspection
Obtain a 0.025 [.001] shim that is suitable for
checking the clearance between the bottoming
surfaces of the crimping jaws. Proceed as follows:
1. Select a terminal and maximum size wire for the
hand tool.
2. Position the terminal and wire between the
crimping jaws, 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 jaws closed.
4. Check the clearance between the bottoming
surfaces of the crimping jaws. 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 (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.
6. REVISION SUMMARY
Since the previous version of this document, the
following changes were made:
:Updated document to corporate requirements.

408- 7114
Rev B4 of 4
76.2 [3.00]
(Closed)
22.2 [.88]
1
Weight: 539g[1lb3oz.]
279.4 [11.00]
2
345
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
121045--3 Ring, Retaining 4
2300432 Pin, Retaining 2
321045--6 Ring, Retaining 2
4300449 Pin, Retaining 1
539364 Spring, Handle 1
Figure 5