TE Connectivity CERTI-CRIMP 90066-7 User manual

©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
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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Instruction Sheet
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 LOC B
408-6610
CERTI-CRIMP* Hand Crimping
Tool 90066-7 and Head
Assembly 90066-9 26 SEP 11 Rev E
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
1. INTRODUCTION
Hand Crimping Tool 90066-7 and Head Assembly
90066-9 (shown in Figure 1) are designed to crimp
Type III+ and Type VI, and commercial MATE-N-LOK*
contacts listed in Figure 2. Read these instructions
thoroughly before crimping any contacts.
All dimensions on this document are in metric units
[withU.S.customaryunitsinbrackets].Figuresand
illustrations are for reference only and are not
drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 6, REVISION SUMMARY.
2. DESCRIPTION (Figures 1 and 2)
The front of the tool (contact side), into which the
contact is inserted, has the tool number marked on it.
The back of the tool (wire side), into which the wire is
inserted, has the wire size and color-code dots
marked above each crimping chamber.
The tool features two fixed dies (crimpers), two
movable dies (anvils), two crimping chambers, a
contact support, a locator/insulation stop, an ejector,
and ratchet.
The ratchet ensures 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 is feature ensures maximum electrical and
tensile performance of the crimp. DO NOT re-
adjust the ratchet.
The locator/insulation stop has two functions. First, it
positions the contact between the crimping dies, and
second, it aids in locating the wire in the contact. In
use, it rests in the locator slot. See Figures 2 and 3.
The contact support prevents the contact from
bending during crimping. The ejector pulls the locator
down and ejects the crimped contact when the tool
handles are FULLY opened.
Type III+ contacts have a color dot located on the
contact spring. Type VI contacts have the
applicable wire size stamped on the underside of
the insulation barrel.
3. CRIMPING PROCEDURE
Refer to Figure 2, and select wire of the specified size
and insulation diameter for the type and part number
of loose piece contact. Strip the wire to the length
indicated. DO NOT cut or nick the wire strands.
On the BACK of the tool, identify the appropriate
crimping chamber (according to the color dot and/or
wire size markings). The markings on the contact must
match the markings on the appropriate crimping
chamber of the tool.
Refer to Figure 3, and proceed as follows:
1. Hold the tool so the BACK (wire side) is facing
you.
2. Make sure the ratchet is released by squeezing
the handles and allowing them to open FULLY.
3. Insert the contact (insulation barrel first) into the
FRONT of appropriate crimping chamber. Position
the contact in the crimpers so that the locator enters
the locator slot of the contact.
Crimpers
Anvils
Front of Tool
(Contact Side)
Ratchet
Contact
Support
NOTE
i
CAUTION
!
NOTE
i
ORIGINAL INSTRUCTIONS

408-6610
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Figure 2
4. 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. Insert a properly stripped wire through the wire
slot in the locator and into wire barrel of the contact
until the insulation butts against the locator/
insulation stop.
Figure 3
WIRE CONTACT CRIMPING
CHAMBER
(Wire Size
Marking)
CRIMPDOT
CODE
SIZE
(AWG) INSULATION DIAMETER TYPE LOOSE PIECE STRIP
PIN SOCKET PIN SOCKET
30-26 1.02-1.52
[.040-.060] III+ 66429 66428 66425 66424 24-20 30-26 2 Dots
28-24 0.89-1.40
[.035-.055] VI 66595 66596 66585 66586 28-24 30-22 1 Dot
26-24 III+ 66107 66109 66106 66108
24-20 1.02-2.03
[.040-.080] III+ 66103 66105 66102 66104 24-20 30-26 2 Dots
VI 66593 66594 66583 66584
30-22 1.02-1.91
[.040-.075] Commercial MATE-N-LOK 61174 61173 350079 350078 28-24 30-22 1 Dot

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Specialprecautionsmustbetakenwheninsertinga
wireintoacontactcrimpedinthecrimpingchamber
marked “24-20/30-26”. The full length of the
stripped wire must rest on the bottom of the wire
barrel. For information concerning this “crush
crimp” technique, refer to Instruction Sheet
408-7497.
6. Holding the wire in place, squeeze the tool
handles until ratchet releases, then remove the
crimped contact.
Damagedcontacts mustnot beused.If adamaged
product is evident, it should be cut from the wire
andreplacedwithanewone.DONOTre-terminate
contacts.
4. MAINTENANCE AND INSPECTION
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations. Though
recommendations call for at least one inspection a
month, frequency of inspection depends on:
— care, amount of use, and handling of the hand
tool
— presence of abnormal amounts of dust and dirt
— degree of operator skill
— your own established standards
The tool is inspected beforebeing shipped; however, it
is recommended that the tool be inspected
immediately upon arrival at your facility to ensure that
the tool has not been damaged during shipment.
4.1. Daily Maintenance
1. The 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, the 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.
DO NOT remove the retaining pins as permanent
damage to the tool could result.
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.
When the tool is not in use, keep handles closed to
prevent objects from becoming lodged in the dies.
Store the tool in a clean, dry area.
SAE is a trademark.
4.2. Periodic Inspection
At least one inspection a month is recommended and
the inspection frequency should be based on the
amount of use, ambient working conditions, operator
training and skill, and company established standards.
A. Lubrication
Keep all pins, pivot points, and bearing surfaces
lubricated with SAE 20 motor oil as follows:
•Tool used in daily production-lubricate daily
•Tool used daily (occasionally)-lubricate weekly
•Tool used weekly-lubricate monthly
Wipe excess oil from the tool, particularly from the
crimping area. Oil transferred from the crimping area
onto certain terminations may affect the electrical
characteristics of an application.
B. Visual Inspection
1. Close the tool handles until the ratchet releases
and then allow them to open freely. If they do not
open quickly and fully, return the tool for evaluation
and repair. See Section 5, REPLACEMENT AND
REPAIR.
2. Inspect the head assembly for worn, cracked, or
broken areas. If damage is evident, return the tool
for evaluation and repair. See Section 5,
REPLACEMENT AND REPAIR.
C. Crimp Height Inspection
This inspection incorporates the use of a crimp height
comparator (micrometer with a modified anvil) as
shown in Figure 4. Detailed information on obtaining
and using a crimp height comparator can be found in
Instruction Sheet 408-7424.
Proceed as follows:
1. Determine the maximum wire size, and select the
applicable contact for the tool (see Figure 1).
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 the dimensions shown
in Figure 4, the tool is considered dimensionally
correct. If not, return the tool for evaluation and repair
(see Section 5, REPLACEMENT AND REPAIR).
CAUTION
!
CAUTION
!
CAUTION
!

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Figure 4
D. Ratchet Inspection
The ratchet should be checked to ensure that it does
not release prematurely, allowing the dies to open
before they have fully bottomed. Obtain a 0.025 mm
[.001 in.] shim that is suitable for checking the
clearance between the bottoming surfaces of the dies,
then proceed as follows:
1. Select a contact and maximum size wire for the
tool.
2. Position the contact and wire in the dies, as
described in Section 3, CRIMPING PROCEDURE.
3. Holding the 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 dies. If the clearance is 0.025 mm
[.001 in.] or less, the ratchet is satisfactory. If
clearance exceeds 0.025 mm [.001 in.], the ratchet
is out of adjustment and must be repaired. See
Section 5, REPLACEMENT AND REPAIR.
5. REPLACEMENT AND REPAIR
The part shown in Figure 5 is customer-replaceable. A
complete inventory can be stocked and controlled to
prevent lost time when replacement of the part is
necessary. Order replacement parts through your TE
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
Revisions to this instruction sheet include:
•Updated document to corporate requirements
•Added product part numbers to table in Figure 4
Figure 5
CONTACT NO.
(Loose Piece)
MAXIMUM
WIRE
SIZE
(AWG)
CRIMPING
CHAMBER
(Wire Size
Marking)
CRIMP
HEIGHT
66429 66428 26 24-20
30-26 1.003 ±0.051 [.0395 ±.0020]
66107
66595 66109 66596 24 28-24 30-22 0.787 ±0.038 [.0310 ±.0015]
66593
66103 66594 66105 20 24-20 30-26 1.003 ±0.051 [.0395 ±.0020]
61173 61174 22 28-24
30-22 0.851 ±0.051 [.0335 ±.0020]