Tyco Electronics CERTI-CRIMP 90418-1 User manual

Instruction Sheet
CERTI- CRIMP* Straight Action
Hand Tool 90418- 1 for 408--9222
LOC B
1of 4
E2011 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products 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.tycoelectronics.com
20 JAN 11 Rev EAMPMODU* Mod IV 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
Front of Tool
Fixed Dies (Crimpers)
Ratchet
Handles
Insulation Crimp
Adjustment Lever
Movable Dies (Anvils)
1. INTRODUCTION
This instruction sheet covers the use of Hand
Crimping Tool 90418--1 which is designed to crimp
AMPMODU Mod IV pin and receptacle contacts onto
wire sizes 26 through 22 AWG having an insulation
diameter range of 1.02 through 1.52 mm [.040
through .060 in.]. Read these instructions thoroughly
before crimping the contacts.
Dimensions on this instruction sheet are in
millimeters [followed by inches in brackets].
Figures are for identification only and are not
drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION (See Figure 1)
The FRONT OF TOOL is marked with the tool
number. The BACK OF TOOL (wire side), into which
the wire is inserted, has the wire size marked above
each crimping chamber.
The tool features two fixed dies (crimpers), two
movable dies (anvils), an insulation crimp adjustment
lever, locator/insulation stop, contact support, ejector,
and ratchet.
The insulation crimp adjustment lever is used to
control the crimp height of the contact insulation
barrel. The locator/insulation stop has two functions: it
positions the contact between the crimping dies and it
aids in locating the wire in the contact. In use, it rests
in the locator slot. The contact support prevents the
contact from bending during the crimping procedure.
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 handles
have been FULLY closed.
The dies bottom before the ratchet releases. This
feature ensures maximum electrical and tensile
performance of the crimped contact. DO NOT
re--adjust the ratchet.
3. CRIMPING PROCEDURE
Strip the wire to the length indicated in Figure 2.
DO NOT cut or nick the wire strands. Select a
contact, and identify the appropriate crimping
chamber (according to the wire size markings on the
BACK of the tool).
ORIGINAL INSTRUCTIONS
NOTE
i
CAUTION
!

408- 9222
Hand Crimping Tool 90418- 1
Rev E2 of 4 Tyco Electronics Corporation
Figure 2
Wire
Barrel
Insulation
Barrel
AMPMODU Mod IV
Receptacle Contact (Shown)
3.56 [.140]
Wire Strip Length
Locator
Slot
Wire Stop
Slot
Note: Not to Scale
Refer to Figure 3 and proceed as follows:
1. Hold the tool so the BACK (wire side) faces you.
2. Make sure the ratchet is released. Squeeze the
tool handles together and allow them to open
FULLY.
3. Looking straight into the BACK of the
appropriate crimping chamber, insert the contact
(insulation barrel first) into the FRONT of the
crimping chamber. Position the contact in the dies
so that the locator enters the locator slot of the
contact.
4. Hold the contact in the locator slot and squeeze
the tool handles together until the anvils start entry
into the crimpers. DO NOT deform the contact
insulation barrel or wire barrel.
5. Insert the stripped wire through the wire slot of
the locator and into the wire barrel of the contact
until the insulation butts against the
locator/insulation stop.
6. Holding the wire in place, squeeze the tool
handles until the ratchet releases.
7. Allow the tool handles to open fully and remove
the crimped contact.
Damaged contacts must be replaced with new
ones. Cut a damaged contact from the wire,
re--strip the wire, and apply a new 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
Figure 3
Back of Tool
(Wire Side)
Stripped Wire
Locator/Insulation Stop
Wire Slot of Locator
Contact Support
Insulation Crimp
Adjustment Lever
Movable Anvils
CAUTION
!

408- 9222
Hand Crimping Tool 90418- 1
3of 4Rev ETyco Electronics Corporation
is too tight or too loose, change the setting
accordingly. The crimp should hold the insulation
firmly without cutting into it.
5. MAINTENANCE AND INSPECTION
5.1. Daily Maintenance
1. 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.
2. Make certain all pivot points and bearing
surfaces are protected with a THIN coat of any
good SAE 20 motor oil. DO NOT oil excessively.
3. When the tool is not in use, keep the handles
closed to prevent objects from becoming lodged
between the crimping dies, and store the tool in a
clean, dry area.
5.2. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the tool and/or be supplied to
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 visual inspections should
be performed in the following sequence:
1. Remove all lubrication and accumulated film by
immersing the tool (handles partially closed) in a
suitable commercial degreaser that will not affect
paint or plastic material.
2. Make certain all retaining pins are in place and
secured with retaining rings. If replacements are
necessary, refer to parts listed in Figure 5.
3. Close the tool handles until the ratchet releases,
then allow handles 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).
4. Inspect the head assembly, with special
emphasis on checking for worn, cracked, or broken
dies. If damage to any part of the head assembly is
evident, return the tool for evaluation and repair
(see Section 6, REPLACEMENT AND REPAIR).
5.3. Crimp Height Inspection
Crimp height inspection is performed through the use
of a micrometer with a modified anvil, commonly
referred to as a crimp height comparator. TE does not
market crimp height comparators.
Proceed as follows:
1. Refer to Figure 4, and select a contact and a
maximum wire size for each crimping chamber.
2. Refer to Section 3, CRIMPING PROCEDURE,
and crimp the contacts accordingly.
3. Using a crimp height comparator, measure wire
barrel crimp height as shown in Figure 4. If the
crimp height conforms to that shown in Figure 4,
the tool is considered dimensionally correct. If not,
return the tool for evaluation and repair (see
Section 6, REPLACEMENT AND REPAIR).
Position Point
on Center of
Wire Barrel
Opposite Seam
Modified Anvil A
+0.05 [+.002]
MAXIMUM WIRE
SIZE (AWG)
TOOL CRIMPING
CHAMBER MARKING
CRIMP HEIGHT
DIMENSION A
24 26--24 0.76 [.030]
22 22 0.86 [.034]
Figure 4
For additional information concerning the use of the
crimp height comparator, refer to Instruction Sheet
408--7424.
5.4. Ratchet Inspection
Obtain a 0.025 [.001] shim that is suitable for
checking the clearance between the bottoming
surfaces of the dies. Then proceed as follows:
1. Select a contact, maximum size wire, and the
designated crimping chamber for the wire being
used.
2. Position the contact and wire between the dies
according to Section 3. Holding the wire in place,
squeeze the tool handles together until the ratchet
releases. Hold the tool handles in this position,
maintaining just enough pressure to keep the dies
closed.
3. Check the clearance between the bottoming
surfaces of the 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).
If the tool conforms to this inspection, lubricate it with
a THIN coat of any good SAE 20 motor oil.

408- 9222
Hand Crimping Tool 90418- 1
Rev E4 of 4 Tyco Electronics Corporation
6. REPLACEMENT AND REPAIR
Customer--replaceable parts are listed in Figure 5.
A complete inventory should 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. Order replacement parts through your
representative, or call 1--800--526--5142, or send a
facsimile of your purchase order to 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.
7. REVISION SUMMARY
Revisions to this instruction sheet include:
SUpdated instruction sheet to corporate
requirements
SAdded Original Instructions to page 1
SModified Paragraph 5.3
SModified Figure 4
Weight: 539g[1lb,4oz] CAUTION:Do not remove the retaining pins; otherwise,
permanent damage to the tool could result.
301.63 [11.88]
63.5 [2.50]
(Handles
Closed)
19.05 [.75]
1
2
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
121045--3 RING, Retaining 4
221045--9 RING, Retaining 2
Figure 5