TE Connectivity Faston Series User manual

Instruction Sheet
1 of 7
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PRODUCT INFORMATION 1-800-522-6752
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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

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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

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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.

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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

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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
GO
NO-GO
GO
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]

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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
1
3-21000-4
Screw, Skt Hd Cap, 10-32 x .375 In. L
1
2 (Not Shown)
21027-3
Wrench, Hex, L-Handle, .050 In.
1
3
21061-1
Screw, Set, Skt, Cone PNT #4-40X, 12
1
Figure 7

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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