TE Connectivity 90080-2 User manual

©2013 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
408-7587
Crimping Dies
90080-2 and 90103 31 MAY 13 Rev A
Figure 1
1. INTRODUCTION
Crimping dies 90080-2 and 90103 are recommended
for crimping the tape-mounted contacts listed in
Figure 2. These dies are designed for use in
Pneumatic Tool 69118-1.
Read this instruction sheet for specific information
concerning the dies, applicable contacts and wire
specifications. Read the instructions (Customer
Manual 409-1773) packaged with the pneumatic tool
for information concerning die insertion, crimping
procedures, and general performance of the tool.
NOTE
Dimensions are in metric units with [inches in brackets].
Figures and illustrations are for reference only and are
not drawn to scale.
For reasons for revision, refer to Section 8, REVISION
SUMMARY.
2. DESCRIPTION
Each die assembly consists of a stationary die and a
moving die.
The stationary dies have chamfered corners and
feature color-coded dots which match the color-coding
on the insulation barrel or wire barrel of the contact.
This color-coding indicates the wire range of the
contact. See Figure 2.
The moving dies have square corners and feature an
alignment plate and wire size markings. Notice that
the die holding screws are also color-coded. This
facilitates mating of the dies and also mates with the
color-coding on the shoulder of the contact. See
Figure 2.
3. CRIMPING PROCEDURE
Determine your application requirements. Then, using
the table in Figure 2, make your selection according to
the following instructions:
Stationary Dies
RedDie Holding
Screw (2 Req) BlueDieHolding
Screw (2 Req)
Red
Yellow
Green
Blue
Violet
WireSize
Markings
WireSize
Markings
Red Blue
Alignment
Plate
Alignment
Plate
Moving Dies
Die Set 90103 Die Set 90080-2
NOTE
i
ORIGINAL INSTRUCTIONS

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Rev A
‡These contacts have no insulation support. †Special short pins. ††Special long pins. Figure 2
A. Die Assembly and Contact Number
Be sure the die assembly you select is compatible with
the contacts to be crimped. The color-code on the
contact shoulder must correspond with the color of the
die holding screw.
B. Wire Size and Insulation Diameter
Make certain the wire and insulation are within the
specified range.
C. Wire Type and Strip Length
Using stranded wire, strip it to the length shown. Do
NOT crimp wire that has cut or nicked strands.
D. Color-Code
Make sure the color-code on the insulation barrel or
wire barrel of the contact matches one of the color-
code dots on the stationary die.
Crimp a contact as follows:
1. Install the dies and contacts according to the
instructions packaged with the pneumatic tool.
2. Make sure the contact is properly positioned
between the dies. Then, insert a stripped wire into
the contact until the wire bottoms in the wire barrel
of the contact.
Color on Shoulder Matches
Color on Die Holding Screw Color on Insulation or Wire
BarrelIndicatesWire Range WireStrip
Length
WireStrip
Length
Insulation Barrel Wire Barrel
Socket Pin Inspection Hole
SOCKET PIN CONTACT SIZE&PIN
DIA
WIRE
SIZE
(AWG)
INSUL
DIA
COLOR-CODE WIRE
STRIP
LENGTH
CRIMPING DIE
BARREL SHOULDER DIE
NO. SCREW COLOR
200331 200334 20 [.040] 24-20 1.40-1.90
[.055-.075] Yellow Red 5.16 [.203] 90103 Red
200333
200335
16 [.062]
18-16 ‡ Blue Blue 6.35
[.250] 90080-2 Blue
200336
200681†
204274
201328 200679† 24-20 1.40-2.16
[.055-.085] Yellow
Red 5.16
[.203] 90103 Red
201330††
204188††
201332 201334†† 28-24 1.22-1.65
[.048-.065] Red
201353 201354 20 [.040] 28-24 1.22-1.65
[.048-.065] Red
201568 201570
16 [.062] 14 ‡ Violet Blue 6.35
[.250] 90080-2 Blue201645†
206029
201580 201578†† 24-20 1.02-1.57
[.040-.062] Yellow Red 5.16 [.203] 90103 Red201647†
201584 201582
20 [.040]201589 201591 18-16 ‡ Blue Blue 6.35
[.250] 90080-2 Blue
201609 201607
28-24 0.89-1.40
[.035-.055] Red Red 5.16 [.203] 90103 Red
201613 201611††
16 [.062]
201649†
204189††
202726 202725 (2) 18 ‡ --- Blue 6.35
[.250] 90080-2 Blue

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Rev A
3. Actuate the machine a complete cycle. Check to
be sure the contact is properly crimped. The wire
must be visible through the inspection hole of the
contact.
4. INSPECTION
4.1. Daily Maintenance
The importance of daily maintenance cannot be over
emphasized, as this can easily and efficiently be
performed after each shift, ensuring satisfactory
performance and continuous production. TE
Connectivity recommends the following:
1. Remove dust, moisture, and other contaminants
with a clean brush or soft lint-free cloth. Do NOT
use objects that could 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.
2. Make sure the proper die holding screws are in
place and secured with the proper retaining rings.
3. Check die alignment and tighten die holding
screws at least twice daily. Make sure the dies are
protected with a THIN coat of any good S.A.E.
No. 20 motor oil. DO NOT OIL EXCESSIVELY.
4. When the dies are not in use, store them in a
clean, dry area.
4.2. Periodic Inspection
Regular inspections should be performed and
recorded by your Quality Control Department with a
record of scheduled inspections remaining with the
dies or supplied to supervisory personnel responsible
for the dies. TE recommends at least one inspection a
month, however, frequency of inspection will depend
on the amount of use, ambient working conditions,
operator training and skill, and your own established
standards. These inspections should be performed in
the following sequence.
A. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable commercial de-
greaser that will not effect paint or plastic material.
2. Make sure all holding screws, retaining rings, and
die components are in place. Refer to the parts
listed in Figure 4 if replacements are necessary.
3. Check all bearing surfaces for wear. Remove and
replace worn components.
4. Inspect the crimp area for flattened, chipped,
cracked, worn, or broken areas. Make sure the
holding screws and the depressions on the
stationary die are properly color-coded. Refer to
Section 2, DESCRIPTION. If damage is evident, the
dies must be repaired before returning to service.
Refer to Section 5, REPAIR AND REPLACEMENT.
B. Mechanical Inspection
This inspection utilizes a GO / NO-GO gage
conforming to the dimensions in Figure 3. TE does not
manufacture or market these gages. Refer to
Instruction Sheet 408-7424.
Proceed as follows:
1. Mate the dies until it is evident that they have
bottomed. Hold the dies in this position with
approximately 69 kPa [10 psi].
2. Align the GO element with the wire barrel
crimping area and push it straight into the crimping
chamber without using force. The GO element must
pass completely through the crimping chamber as
shown in Figure 3.
3. Now 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 3.
If the crimping chambers conform to the gage
inspection, the dies are considered dimensionally
correct and should be lubricated with a THIN coat of
oil. If not, the dies must be repaired before returning
them to service. Refer to Section 5, REPAIR AND
REPLACEMENT.
Figure 3
5. REPAIR AND REPLACEMENT
The parts listed in Figure 4 are customer replaceable
parts. A complete inventory can be stocked and
controlled to prevent lost time when replacement of
parts is necessary. The dies can also be returned to
TE for evaluation and repair. Send the dies and a
written description of the problem to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
CRIMPING DIE
NUMBER GAGE DIMENSION
GO (DIA) NO-TO (DIA)
90080-2 1.54 [.0605] 1.613 [.0635]
90103 1.003 [.0395] 1.080 [.0425]
Suggested Plug Gage Design
End View End View
GO Element NO-GO Element
WireBarrel
Crimping
Chamber

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Rev A
6. REVISION SUMMARY
•Deleted product trademark name in all instances
•Updated document to corporate requirements
Figure 4
DIE SPECIFICATIONS REPLACEMENT PARTS
DIE NO. DIMENSION WEIGHT ITEM DESC PART NUMBER FOR: QTY PER
SET
A B C 90080-2 90103
90080-2 15.88
[.625] 33.32 [1.312] 26.59 [1.047]
0.834 N
[3 Oz]
1 SCREW, Die Holding 1-306105-5 306105-7 1
2 CRIMPER, Insulation 125401-2 45283 1
3 CRIMPER, Wire 125398-4 125398-1 1
4 PLATE, Alignment 125180-2 125180-2 1
5 SCREW, Die Holding 306624-8 306624-5 1
90103 15.88
[.625] 33.32 [1.312] 26.59 [1.047]
6 ANVIL, Insulation 125402-2 45284 1
7 ANVIL, Wire 125399-5 125399-1 1
8 SPACER SUPPORT, Upper 125400-6 125400-1 1
9 RING, Retaining 1-21046-3 1-21046-3 2
10 SPACER SUPPORT, Lower 1-125154-8 125154-2 1