TE Connectivity 90331- 1 User manual

Instruction Sheet
Straight Action Hand Tool 90331- 1 408--7773
1of 4
.2012 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.
TO OLI NG 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
12 JUN 12 Rev Cfor Type III(+) Contacts
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
90331--1
Insulation Crimping
Adjustment Lever
Front Side
of Tool
Contact
Support
Anvil
(Movable Die)
Crimper
(Fixed Die)
Ratchet
1. INTRODUCTION
Straight Action Hand Tool 90331--1 is designed to
crimp the Type III(+) loose piece (LP) pin and socket
contacts listed in Figure 2. Read these instructions
thoroughly before using the hand tool.
Dimensions on this sheet are in metric units [with
U.S. customary equivalents in brackets].
Reasons for reissue of this document are provided in
Section 7, REVISION SUMMARY.
2. DESCRIPTION (Figure 1)
The hand tool features a crimper (fixed die), an anvil
(movable die), an insulation crimping adjustment
lever, a locator/insulation stop, a contact support, an
ejector, and a ratchet. The front side of the tool, into
which the contact is inserted, has the tool number
marked on it. The wire is inserted from the back side
of the tool which is marked above each crimping
chamber.
The insulation crimping adjustment lever is used to
regulate the crimp height of the contact insulation
barrel. The contact support prevents the contact from
bending during the crimping procedure.
The locator/insulation stop positions the contact
between the dies and aids in locating the wire in the
contact. In use, it rests in the contact locator slot. The
ejector pulls the locator down and ejects the crimped
contact when the tool handles are fully opened.
The ratchet ensures full crimping of the contact. Once
engaged, the ratchet will not release until the tool
handles have been FULLY closed.
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.
Wire Strip
Length
NOTE: Not to Scale
Insulation
Barrel
Wire
Barrel
Locator
Slot
WIRE
S
I
Z
E
IN
S
U
LCONTACT WIRE
S
T
R
I
P
SIZE
(AWG)
I
N
S
U
L
DIA TYPE LP STRIP STRIP
LENGTH
1
5
2
3
4
3
Socket 66565--[ ] 66563--[ ]
3
9
6
0
3
8
24 -- 20 1.52--3.43
[.060--.135] Pin 66566--[ ]
213605--[ ]
66564--[ ]
213605--[ ]
3.96+0.38
[.156+.015]
Figure 2
NOTE
i
CAUTION
!

408- 7773
Rev C2 of 4
3. CRIMPING PROCEDURE
Select the appropriate wire size and loose piece
contact 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 indicated in
Figure 2. Do NOT nick or cut the wire strands.
1. Hold tool so that the back side is facing you.
2. Open the dies by squeezing the tool handles
together until the ratchet releases.
3. Insert the contact insulation barrel from the front
side of the tool into the crimping chamber. Position
the contact on the anvil so that the locator/
insulation stop enters the contact locator slot. Push
contact in until wire barrel butts against
locator/insulation stop. See Figure 3.
4. Holding the contact in place, squeeze the tool
handles together just enough to hold the contact in
the crimping chamber.
Do NOT deform the contact insulation barrel or
wire barrel.
5. Insert stripped wire through the locator and into
the contact wire barrel. The wire should extend
slightly beyond the end of the wire barrel and
the wire insulation should butt against the
locator/insulation stop.
6. Holding the wire in place, squeeze tool handles
together until ratchet releases.
7. Allow tool handles to open FULLY and remove
crimped contact from tool.
4. INSULATION CRIMPING ADJUSTMENT
The hand tool has three insulation crimping
adjustment positions to adjust the wire insulation grip:
1—Tight, 2—Medium, and 3—Loose. To determine
the proper insulation crimp setting, proceed as
follows:
1. Slide the insulation crimping adjustment lever to
Position 3 (marked on the back side of the tool).
2. Position contact into crimping chamber as
described in Section 3, CRIMPING PROCEDURE.
3. Insert an UNSTRIPPED wire into just the
insulation barrel. Crimp contact and remove from
crimping chamber.
4. Check the insulation support by bending the
wire back and forth once. The insulation barrel
should retain grip on the wire insulation. If the wire
pulls out, move the insulation crimping adjustment
lever to the next tighter position and perform
another test crimp. If the wire does not pull out, the
lever is properly adjusted and the hand tool is
ready for crimping.
Adjust the lever as necessary until the desired
insulation grip is obtained. Crimp should hold
wire insulation firmly without cutting into it. Do
NOT use a tighter grip than necessary.
Figure 3
Ejector
Contact
Support
Anvil
Back Side
of Tool
Locator/Insulation
Stop Must Enter
Contact Locator Slot
Stripped
Wire
Crimp Section
Wire Size
Marking
Wire Barrel
Locator Slot
Butt Wire Barrel
Against Locator
NOTE
NOTE

408- 7773
3of 4Rev C
5. MAINTENANCE AND INSPECTION
Tyco Electronics recommends 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:
1. The care, amount of use, and handling of the
hand tool.
2. The presence of abnormal amounts of dust and
dirt.
3. The degree of operator skill.
4. Your own established standards.
The hand tool is inspected before being shipped;
however, Tyco Electronics recommends that the tool
be inspected immediately upon arrival to ensure that
the tool has not been damaged during shipment.
5.1. 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.
Do NOT remove retaining pins as permanent
damage to the tool may result. See Section 6,
REPLACEMENT AND REPAIR.
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.
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.
5.2. 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 6, REPLACEMENT AND
REPAIR.
2. Inspect the head for worn, cracked, or broken
areas. If damage is evident, return the tool to
Tyco Electronics for evaluation and repair. See
Section 6, REPLACEMENT AND REPAIR.
Figure 4
66565--[ ] 1.07--0.86 [.042--.034]
Position Point on
Center of
Wire Barrel
Opposite Seam
Modified
Anvil “A”
66566--[ ] 0.97--0.76 [.038--.030]
213605--[ ] 1.02--0.81 [.040--.032]
WIRE SIZE
AWG
(Max.)
CONTACT
NUMBER
(LP)
20
CRIMP SECT
WIRE SIZE
MARKING
(2) 24
24
22
1.12--0.91 [.044--.036]20
CRIMP
HEIGHT
DIM. “A”
C. Crimp Height Inspection
Crimp height inspection is performed using a
micrometer with a modified anvil, commonly referred
to as a crimp height comparator. Refer to instruction
sheet 408--7424 for detailed information on obtaining
and using a crimp height comparator.
Proceed as follows:
1. Select a contact and maximum size wire for the
crimping chamber.
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp 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 6, REPLACEMENT AND REPAIR.
CAUTION

408- 7773
Rev C4 of 4
D. Ratchet Inspection
The ratchet feature on hand tools should be checked
to ensure that the ratchet does not release
prematurely, allowing the 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 and 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 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 6, REPLACEMENT AND REPAIR.
6. 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 717--986--7605, or write to:
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
Parts other than those specified in Figure 5 must be
replaced by TE to ensure reliability of the tool. Tools
may be returned to TE for evaluation and repair. For
tool repair service, contact a TE Representative at
1--800--526--5136
7. REVISION SUMMARY
Since the previous version of this document, the
following changes were made:
:Updated document to corporate requirements
(company name and logo, document format).
:Corrected trademark references in ratchet
descriptions.
:Updated crimp height comparator
information.
19.05 [.75]
1
Weight:
539 g
[1lb4oz]
301.2
[11.86]
2
63.5
[2.50]
(Closed)
90331--1
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
1
2
21045--3
21045--9
RING, Retaining
RING, Retaining
4
2
Figure 5