Tyco Electronics 90301-2 User manual

Instruction Sheet
408-7909
LOC B
1 of 4
E 2008 Tyco Electronics Corporation, Harrisburg, PA
All International ights eserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTE 1-800-722-1111
P ODUCT INFO MATION 1-800-522-6752 This controlled document is subject to change. For latest revision and egional Customer Service,
visit our website at www.tycoelectronics.com
25 NOV 08 ev C
Hand Crimping Tool 90301-2
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresult fromtheprolongeduseofmanuallypoweredhand tools.Handtoolsareintendedforoccasional useandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Figure 1
Insulation Crimp
Adjustment Lever
Front of Tool
(Contact Side)
Anvils
Crimpers
Contact
Support
90301-2
CE TI-C IM
P
Hand Crimpin
g
Tool atchet
Control
1. INTRODUCTION
AMP* Hand Crimping Tool 90301–2 is designed to
crimp the Tandem Spring loose piece (LP) contacts
listed in Figure 1. Read these instructions thoroughly
before using the tool.
All dimensions in this document are in millimeters
[ ith inches in brackets]. Illustrations are not
dra n to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION (Figure 1)
This tool features two fixed dies (crimpers), two
movable dies (anvils), an insulation crimp adjustment
lever, a contact locator/insulation stop, an inner and
outer contact support, and a CERTI–CRIMP hand
crimping tool ratchet control.
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 locator/insulation stop positions the
contact between the crimping dies. In addition, the
locator/insulation stop aids in locating the wire in the
contact. In use, it rests in the contact locator slot. See
Figures 2 and 3.
The inner and outer contact supports prevent the
contact from bending during the crimping operation.
The CERTI–CRIMP 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.
Insulation Barrel
Locator Slot
Wire Barrel
Strip Length
3.56 [.140]
WIRE CONTACT NUMBER CRIMP
SECTION
SI E
(AWG)
I NSUL
DIA LOOSE PIECE STRIP
SECTION
(Wire Size
Marking)
530553-5 530553-2,
-7
,
-4, -6
26 to 22 0.91 - 1.42
[.036-.056] 531216-2,
-4 531216-1, -3 26-22
531224-7 531224-6
32 to 28 0.64 - 1.37
[.025-.054] 530901-3, -5, -7 530901-2, -4, -6 32-28
Figure 2
NOTE
i
CAUTION
!

408-7909
Hand Crimping Tool 90301-2
Rev C2 of 4 Tyco Electronics Corporation
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.
4. Position the contact in the crimpers so that the
locator/insulation stop enters the locator slot in 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.
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
5.1. Daily Maintenan e
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.
Figure 3
26-22
32-28
Stripped Wire
Locator/Insulation
Stop
Back of Tool
(Wire Side) Outer Contact Support
Inner Contact Support
Insulation
Anvil
Locator Slot
(In Contact)
Insulation
Cri per
Cri p Section
Wire Size Marking

408-7909
Hand Crimping Tool 90301-2
3 of 4Rev C
Tyco Electronics Corporation
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 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:
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 tool, 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
This inspection requires the use of 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
contact and a wire (maximum size) for each crimp
section.
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the contact(s) 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 6, REPLACEMENT AND REPAIR).
For additional information concerning the use of the
crimp height comparator, refer to Instruction Sheet
408–7424.
Position Point on
Center of Wire Barrel
Opposite Seam
Mo ifie
Anvil
A"
+0.05
[+.002]
CONTACT
N MBER (LP) WIRE SIZE AWG (Max.)
CRIMP SECT
(Wire Size
Marking)
CRIMP
HEIGHT
DIM. A"
530553-5,-7
531216-2,-4
531224-7 22 26-22 0.76 [.030]
530901-3,-5,-7 28 32-28 0.56 [.022]
Figure 4
C. CERTI-CRIMP Hand Crimping Tool Ratchet Control
Inspection
Obtain a 0.025–mm [.001–in.] 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 CERTI–CRIMP 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.
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.

408-7909
Hand Crimping Tool 90301-2
Rev C4 o 4 Tyco Electronics Corporation
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 Tyco Electronics 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.
7. RE ISION SUMMARY
Since the previous release, the logo was updated.
19.0 [.75]
12
Do not remove the retaining pins or permanent damage to the tool may result.
WEIGHT: 567 g [1 lb. 4 oz.]
F
AMP
90301-2
301.8 [11.88]
63.5 [2.50]
(Closed)
CAUTION
!
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QUANTITY PER TOOL
1 21045-3 Ring, Retaining 4
2 21045-6 Ring, Retaining 2
Figure 5