TE Connectivity Faston Series User manual

Instruction Sheet

1 of 7

*Trademark

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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.

408-9279

20 AUG 19 Rev F

Figure 1

INTRODUCTION

Platform Crimping Die Assemblies 90390-3 and 90391-3 are used in Platform Hand Tool Frame 58078-3

(Instruction Sheet 408-6976). The die assemblies crimp the Ultra-Fast Fully Insulated FASTON* Terminals

listed in Figure 2.

Read These instructions before using the Platform Hand Tool Frame and Platform Crimping Dies.

NOTE

Dimensions are in millimeters [with inch equivalents in brackets]. Figures are for identification only and are not drawn to scale.

Reasons for reissue are provided in Section 7, REVISION SUMMARY.

DESCRIPTION

Each die assembly consists of an upper die (crimper) and a lower die (anvil), a retaining screw (on the upper

die), and a hex wrench for securing the lower die to the platform of the hand tool frame.

The die assemblies are identified by part numbers, color dot codes, and applicable wire range designations

(see Figure 1). The 90390-3 die assembly has a red color dot on both the crimper and the anvil, while the

90391-3 die assembly has a blue color dot on the crimper and the anvil. The color coding on the die assembly

corresponds to the color coding on the translucent insulation of the Ultra-Fast FASTON terminal for easier

identification when crimping.

INSTALLATION

Determine the part number of the terminal you are crimping, then refer to the table in Figure 2 and select the

appropriate die assembly. Install dies as described below.

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.

Crimping Die Assemblies

90390-3 and 90391-3

408-9279

Rev F

2 of 7

WIRE

TERMINAL

DIE

WIRE SIZE

(AWG

INSUL DIA

(MAX)

SERIES

TYPE

COLOR

CODE

LOOSE

PIECE

STRIP

DIE

NUMBER

CRIMP

SYMBOL

(DOT CODE)

22-18

3.04 [.120]

110

In-Line Recpt

Red

520081

520080

90390-3

1 Dot

3.04 [.120]

110

In-Line Recpt

520084

520083

1 Dot

3.04 [.120]

110

In-Line Recpt

520273

520272

1 Dot

5.84 [.230]

110

In-Line Recpt

---

520306

1 Dot

3.43 [.135]

187

In-Line Recpt

520182

520181

1 Dot

3.43 [.135]

187

In-Line Recpt

520194

520193

1 Dot

4.19 [.165]

187

Flag Recpt

520335

520334

Plain (No Mark)

4.19 [.165]

187

Flag Recpt

520337

520336

Plain (No Mark)

5.84 [.230]

187

In-Line Recpt

---

520261

1 Dot

5.84 [.230]

187

In-Line Recpt

520275

520274

1 Dot

3.43 [.135]

250

In-Line Recpt

520184

520183

1 Dot

5.84 [.230]

250

In-Line Recpt

520264

520263

1 Dot

3.43 [.135]

250

In-Line Tab

520103

520102

1 Dot

4.19 [.165]

250

Flag Recpt

520129

520128

Plain (No Mark)

16-14

6.60 [.260]

110

In-Line Recpt

Blue

---

520370

90391-3

2 Dots

4.06 [.160]

187

In-Line Recpt

350816

350815

2 Dots

4.06 [.160]

187

In-Line Recpt

520125

520124

2 Dots

4.70 [.185]

187

Flag Recpt

520339

---

Plain (No Mark)

4.70 [.185]

187

Flag Recpt

---

520340

Plain (No Mark)

6.60 [.260]

187

In-Line Recpt

520151

520150

2 Dots

4.06 [.160]

187

In-Line Recpt

350820

350819

2 Dots

4.06 [.160]

250

In-Line Recpt

520117

520116

2 Dots

6.60 [.260]

250

In-Line Recpt

520141

520140

2 Dots

4.06 [.160]

250

In-Line Tab

520107

520106

2 Dots

4.70 [.185]

250

Flag Recpt

520133

520132

Plain (No Mark)

4.19 [.165]

250

Flag Recpt

520129

520128

Plain (No Mark)

5.84 [.230]

250

Flag Recpt

---

520856

Plain (No Mark)

Figure 2

408-9279

Rev F

3 of 7

3.1. Installing Lower Die Assembly

1. Squeeze the tool handles together until they bottom. Then allow them to open fully.

2. Hold the hand tool frame so that the back of the tool is facing you and note the socket head screw

located in the lower die platform (see Figure 3).

Figure 3

3. Slide the lower die onto the lower platform, ensuring that the drilled holes on the side of the lower die

line up with the socket head screw.

NOTE

If the lower die will not seat on the lower die platform with the drilled hole aligned with the socket head screw, use the hex wrench to turn

the screw either in or out until the set screw does not protrude from either side of the lower tool jaw.

4. With the lower die in place, turn the socket head screw (on the die platform) clockwise until snug. Do

NOT overtighten.

3.2. Installing Upper Die Assembly

1. Remove the die retaining screw from the die assembly.

2. Position the upper die in upper die platform of the tool. Thread the die retaining screw through the

mounting hole in the top of tool and tighten the screw until it is snug but NOT secured.

3. While guiding the upper die into alignment with the lower die, slowly close the tool handles until the

dies bottom.

4. Tighten the upper die retaining screw until the die is secure.

5. Squeeze the tool handles together until the ratchet releases. Allow the tool handles to open fully. The

tool is now ready for use.

CRIMPING PROCEDURE

1. Refer to the table in Figure 2, select a wire of the specified size and strip the wire to the dimension

provided. Do NOT nick or cut the wire strands.

2. Select an applicable contact (see Figure 2).

3. Hold the tool so the front of the tool is facing you.

408-9279

Rev F

4 of 7

4. Make sure the ratchet is released. Squeeze the tool handles together and allow them to open fully.

5. Rotate the blue plastic locator stop index to the appropriate position.

When crimping a 110 Series terminal, rotate the index until the number “110” appears in the

uppermost position.

When crimping a 187 or 250 Series terminal, rotate the index until the numbers “250-187” appear in

the uppermost position.

6. Insert the terminal into the proper crimp section.

In-line terminals may be crimped in either in-line section.

Flag terminals must be crimped in the flag crimp section (see Figure 4).

For in-line terminals, the flat side of the terminal must seat on the locator.

For flag terminals, the flat side of the wire end must face outward and the mating end must seat on

the locator.

Figure 4

7. Squeeze the tool handles sufficiently to hold the terminal firmly in place without deforming it.

8. Insert a properly stripped wire into the barrel of the terminal.

9. Hold the wire in place and squeeze the tool handles until the ratchet releases.

10. Allow the tool handles to open fully and remove the crimped terminal.

MAINTENANCE/INSPECTION

5.1. Daily Maintenance

Remove all foreign particles with a clean, soft brush or a clean, soft, lint-free cloth. Do NOT use materials or

objects that can damage the dies. If foreign matter cannot be removed easily, or if the proper replacement parts

are not available, return the dies to your supervisor.

Make certain the dies are protected with a THIN coat of any good SAE 20 motor oil. DO NOT OIL

EXCESSIVELY.

When the dies are not in use, mate them and store in a clean, dry area.

SAE is a trademark

408-9279

Rev F

5 of 7

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 per 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 dies in a suitable degreaser that will not

affect paint or plastic material.

2. Make sure all die holding screws and die components are in place. Refer to parts listed in Figure 7 if

replacements are necessary.

3. Check all bearing surfaces. Remove and replace worn components.

4. Inspect the crimp area for flattened, chipped, cracked, worn or broken areas. If damage is evident, the

dies must be repaired before returning them to service. Refer to Section 6; REPLACEMENT AND

REPAIR.

5.3. Gaging the Crimping Chamber

This inspection requires the use of a plug gage conforming to the dimensions in Figure 5.

NOTE

TE Connectivity does not manufacture or market these gages.

Figure 5

Proceed as follows:

1. Mate the dies until it is evident that they have bottomed. Hold the dies in this position with a pressure

of approximately 69 kPa [10 psi].

2. Align the GO element with the wire barrel crimping chamber. Push element straight into the crimping

chamber without using force. The GO element must pass completely through the crimping chamber as

shown in Figure 6.

Platform

Die

Number

Terminal

No. (Lp)

Element Diameter

Platform

Die

Number

Terminal

No. (Lp)

Element Diameter

NO-GO

90390-3

520081

520084

520273

520182

520194

520275

520184

520264

520103

520129

520335

520337

1.575-1.582

[.0620-.0623]

1.725-1.727

[.0679-.0680]

90391-3

350616

520125

520151

350820

520117

520107

520141

520133

520339

1.829-1.836

[.0720-.0723]

1.979-1.981

[.0779-.0780]

408-9279

Rev F

6 of 7

3. Align the NO-GO element and try to insert it straight into the same crimping chamber. The NO-GO

element may start entry but must not pass completely through, as shown in Figure 6.

Figure 6

If the crimping chamber conforms to the gage inspection, the dies are considered dimensionally correct and

should be lubricated with a THIN coat of SAE 20 motor oil. If not, the dies must be repaired before returning

them to service.

For additional information concerning the use of a plug gage, refer to Instruction Sheet 408-7424.

REPLACEMENT AND REPAIR

The parts listed in Figure 7 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

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)

TE CONNECTIVITY CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

Dies may be returned to TE for evaluation and repair. For tool repair service, contact a TE Representative at

1-800-526-5136.

Item No.

Part Number

Description

Qty Per Die

3-21000-4

Screw, Skt Hd Cap, 10-32 x .375 In. L

2 (Not Shown)

21027-3

Wrench, Hex, L-Handle, .050 In.

21061-1

Screw, Set, Skt, Cone PNT #4-40X, 12

Figure 7

408-9279

Rev F

7 of 7

REVISION SUMMARY

Updated format to reflect most current corporate format, logo and enterprise name

Revised Figure 1 Wire Size Column from 22-16 to 22-18

Relocate several figures to more closely align with applicable text

Split original Figure 5 into 2 figures; changed references and Figuring numbering accordingly.

Removed Hex wrench pictorial from original Figure 6; made notation in table

Activated hot links to reference documents

Added SAE trademark reference

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