TE Connectivity 90382- 2 User manual

Instruction Sheet
408--6561
LOC B
1of 4
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
TE logo is a trademark.
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
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
16 Mar 11 Rev DHand Crimping Tool 90382- 2
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
Front Side
of Tool
Contact
Locator
Crimpers
Anvils
Ratchet
1. INTRODUCTION
Hand Crimping Tool 90382--2 (shown in
Figure 1) is designed to crimp the Type XII Contacts
listed in Figure 2. Read these instructions thoroughly
before using the tool.
Dimensions are in millimeters [followed by
inch equivalents in brackets]. Figures are for
identification only and are not drawn to scale.
Reasons for re--issue can be found in Section 6,
REVISION SUMMARY.
2. DESCRIPTION
The hand tool features two fixed crimping dies
(crimpers) and two movable crimping dies (anvils), a
contact locator, a wire stop, and a CERTI--CRIMP*
Hand Crimping Tool Ratchet Control. See Figure 1.
The contact locator positions the contact between the
crimping dies. In use, the contact locator rests in the
locator slot of the contact.
Thewirestopaidsinlocatingthewireinthecontact.
In use, the wire stop rests in the wire stop slot of the
contact.
The ratchet ensures full crimping of the contact. Once
engaged, the ratchet will not release until the handles
have been fully closed.
The crimping dies bottom before the ratchet
releases. This design feature ensures maximum
electrical and tensile performance of the crimp.
Do NOT re--adjust the ratchet.
Wire
Stop Slot
Pin Contact
Insulation
Barrel
Wire
Barrel
Locator
Slot
Insulation
Barrel
Locator
Slot
Wire
Barrel
Socket
Contact
Wire
Stop Slot
Wire
Strip
Length
WIRE CONTACT
SIZE
(AWG)
INSUL
DIA
STRIP
LENGTH TYPE LOOSE PIECE STRIP
3
6
8
4
1
9
6
3
5
P
i
n
66261 66255
16 to 12 3.68--4.19
[
.145--.165
]
6.35
[
.25
]
P
i
n66262 66256
[
.
1
4
5
-
-
.
1
6
5
]
[
.
2
5
]
Socket 66746 66252
Figure 2
NOTE
i
CAUTION
!

408- 6561
Rev D2 of 4
Figure 3
Front Side
of Tool
(Wire Side)
Stripped
Wire
Contact
Locator
Wire Slot in Locator
Insulation Barrel
Locator Slot
in Contact
Wire Slot
in Contact
Wire Stop
3. CRIMPING PROCEDURE
Refer to Figure 2 and select the appropriate contact
and wire size for the hand tool. The wire size and
insulation diameter must be within the specified range
for the contact. Strip the wire to the length shown in
Figure 2. Do NOT nick or cut the wire strands.
1. Open crimping dies by squeezing the tool
handles together until the ratchet releases.
2. Insert the contact insulation barrel into the
crimping chamber on the anvil crimping die from
the BACK side of tool. Position contact so that the
contact locator enters the locator slot in the
contact. See Figure 3.
3. Holding contact in position, squeeze tool
handles together just enough to hold the contact in
the crimping dies. Do NOT deform the insulation
barrel or wire barrel.
4. Insert stripped wire through wire slot in contact
locator and into wire barrel of contact until the wire
butts against the wire stop.
5. Holding wire in place, squeeze tool handles
together until ratchet releases.
6. Allow tool handles to open FULLY and remove
crimped contact from tool.
4. MAINTENANCE AND INSPECTION
A periodic maintenance and inspection program is
recommended to ensure dependable and uniform
terminations. Though recommendations call for at
least one inspection a month, frequency of inspection
depends on:
SThe care, amount of use, and handling of the
hand tool,
SThe presence of abnormal amounts of dust
and dirt,
SThe degree of operator skill, and
SYour own established standards.
Although the hand tool is inspected before being
shipped, it should be inspected immediately upon
arrival at your facility to ensure that it has not been
damaged during shipment.
4.1. Daily Maintenance
1. Hand tool should be immersed (handles partially
closed) in a reliable commercial degreasing
compound to remove accumulated dirt, grease,
and foreign matter. When degreasing compound is
not available, tool may be wiped clean with a soft,
lint--free cloth. Do NOT use hard or abrasive
objects that could damage the tool.
2. Make certain that the retaining pins are in place
and that they are secured with retaining rings.
3. All pins, pivot points, and bearing surfaces
should be protected with a THIN coat of any good
SAE 20 motor oil. Do NOT oil excessively.

408- 6561
3of 4Rev D
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. Periodic Inspection
A. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with SAE 20 motor oil as follows:
Tool used in daily production—lubricate daily
Tool used daily (occasional)—lubricate weekly
Tool 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.
B. Visual Inspection
1. 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.
2. Inspect head assembly for worn, cracked, or
broken dies. If damage is evident, return the tool to
TE for evaluation and repair. See Section 5,
REPLACEMENT AND REPAIR.
C. Crimp Height Inspection
This inspection requires the use of a micrometer with
a modified anvil. TE does not manufacture or market
these gages, however TE recommends a modified
micrometer (Crimp Height Comparator
RS--1019--5LP).
Proceed as follows:
1. Select a contact and wire for the crimping
chamber.
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the contact accordingly.
3. Using the crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. If the
crimp height conforms to that height, the tool is
considered dimensionally correct. If not, the tool
must be returned for evaluation and repair. See
Section 5, REPLACEMENT AND REPAIR.
For additional information concerning the use of the
crimp height comparator, refer to instruction sheet
408--7424.
Figure 4
Position Point
on Center of
Wire Barrel
Opposite
Seam
Modified
Anvil Crimp Height
2.39+0.08
[.094+.003]
D. Ratchet Inspection
The ratchet feature on these 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 [.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 wire for the tool.
2. Position the contact and wire between the
crimping dies, as described in Section 3,
CRIMPING PROCEDURE.
3. Holding wire in place, squeeze the handles 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
clearance exceeds 0.025 [.001], the ratchet is out
of adjustment and must be repaired. See Section
5, REPLACEMENT AND REPAIR.

408- 6561
Rev D4 of 4
82.6
[3.25]
(Closed)
25.4
[1.00]
311.2
[12.25]
3 4
1 2
Weight: 936g[2lb,1oz]
CUSTOMER REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
121045--3 RING, Retaining 4
2300388 PIN, Retaining 2
321045--6 RING, Retaining 2
4300389 PIN, Retaining 1
Figure 5
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. Parts other than those listed
should be replaced by TE to ensure quality and
reliability of the tool. Order replacement parts through
your TE representative, or call 1--800--526--5142, or
send a facsimile of your purchase order to
717--986--7605, or write to:
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
Tools may also be returned for evaluation and repair.
For tool repair service, contact a TE Representative
at: 1--800--526--5136.
Contacts are not repairable once a termination
has been made. Any defective contact should be
removed and replaced with a new one.
6. REVISION SUMMARY
The following changes were made since the previous
release of this sheet:
SUpdated document to corporate requirements.
CAUTION
!