Tyco Electronics 90390-3 User manual

Instruction Sheet
Cr mp ng D e Assembl es 408-9279
E 2006 yco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
yco is a trademark. * rademark
Other products, logos, and company names used are the property of their respective owners. LOC B
1 of 5
OOLING ASSIS ANCE CEN ER 1-800-722-1111
PRODUC INFORMA ION 1-800-522-6752 his controlled document is subject to change. For latest revision and Regional Customer Service,
visit our website at www.tycoelectron cs.com
25 JUL 06 Rev B
90390-3 and 90391-3
PROPER USE GUIDELINES
Cumulative raumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Figure 1
Die Retaining
Screw
Upper Die
Assembly
(Crimper)
Lower Die
Assembly
(Anvil)
Color
Code
Crimp Symbol
(Dot Code)
1. INTRODUCTION
Platform Crimping Die Assemblies 90390–3 and
90391–3 are used in Platform Hand Tool Frame
58078–3 (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.
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.
2. 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 translucent insulation of the Ultra–Fast
FASTON terminal for easier identification when
crimping.
3. 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.
3.1. Install ng Lower D e Assembly
1. Squeeze the tool handlers 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.
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.
If the lower die will not seat on the lower die
platform with the drilled hole aligned with the
socket head screw, use the he 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. Install ng Upper D e 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.
NOTE
NOTE

408-9279
Crimping Die Assemblies 90390-3 nd 90391-3
Rev B2 of 5
In-Line
Re epta le
Terminal
In-Line Tab
Terminal Flag Re epta le
Terminal
Wire Size and
Series Number
Wire Barrel
Wire Strip
Length (Typ)
7.14
[.281]
Translu ent
Insulation (Typ)
WIRE TERMINAL DIE
WIRE SIZE
(AWG) INSUL DIA (M x) SERIES TYPE COLOR CODE LP STRIP DIE NUMBER CRIMP SYMBOL
(Dot Code)
22-16 3.04 [.120] 110 In-Line Re pt Red 520081 520080 90390-3 1 Dot
3.04 [.120] 110 In-Line Re pt 520084 520083 1 Dot
3.04 [.120] 110 In-Line Re pt 520273 520272 1 Dot
5.84 [.230] 110 In-Line Re pt -- 520306 1 Dot
3.43 [.135] 187 In-Line Re pt 520182 520181 1 Dot
3.43 [.135] 187 In-Line Re pt 520194 520193 1 Dot
4.19 [.165] 187 Flag Re pt 520335 520334 Plain (No Mark)
4.19 [.165] 187 Flag Re pt 520337 520336 Plain (No Mark)
5.84 [.230] 187 In-Line Re pt -- 52061 1 Dot
5.84 [.230] 187 In-Line Re pt 520275 520274 1 Dot
3.43 [.135] 250 In-Line Re pt 520184 520183 1 Dot
5.84 [.230] 250 In-Line Re pt 520264 520263 1 Dot
3.43 [.135] 250 In-Line Tab 520103 520102 1 Dot
4.19 [.165] 250 Flag Re pt 520129 520128 Plain (No Mark)
16-14 6.60 [.260] 110 In-Line Re pt Blue -- 520370 90391-3 2 Dots
4.06 [.160] 187 In-Line Re pt 350816 350815 2 Dots
4.06 [.160] 187 In-Line Re pt 520125 520124 2 Dots
4.70 [.185] 187 Flag Re pt 520339 -- Plain (No Mark)
4.70 [.185] 187 Flag Re pt -- 520340 Plain (No Mark)
6.60 [.260] 187 In-Line Re pt 520151 520150 2 Dots
4.06 [.160] 187 In-Line Re pt 350820 350819 2 Dots
4.06 [.160] 250 In-Line Re pt 520117 520116 2 Dots
6.60 [.260] 250 In-Line Re pt 520141 520140 2 Dots
4.06 [.160] 250 In-Line Tab 520107 520106 2 Dots
4.70 [.185] 250 Flag Re pt 520133 520132 Plain (No Mark)
4.19 [.165] 250 Flag Re pt 520129 520128 Plain (No Mark)
5.84 [.230] 250 Flag Re pt -- 520856 Plain (No Mark)
Figure 2

408-9279
Crimping Die Assemblies 90390-3 an 90391-3
3 of 5Rev B
Figure 3
Uppe Die
Lowe Die
Locato
Setsc ew
(Flush
on Both
Sides)
Die
Stop
Die Retaining
Sc ew
4. 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 that the front of the tool is
facing you.
4. Make sure that 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.
S When crimping a 110 series terminal, rotate the
index until the number “110” appears in the
uppermost position.
S 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.
S For in–line terminals, the flat side of the
terminal must seat on the locator.
S For flag terminals, the flat side of the wire end
must face outward and the mating end must
seat on the locator.
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.
5. 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 and store them in
a clean, dry area.
Figure 4
O ientation fo
Tab and Receptacle Flat Su face of
Te minal
Flat Side of
Wi e End
O ientation fo
Flag Te minal Anvil
Locato
Locato
Stop Index
F ont of Tool
(Te minal Side) Tool
F ame

408-9279
Crimping Die Assemblies 90390-3 and 90391-3
Rev B4 of 5
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 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 toe parts listed in
Figure 6 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, REPAIR.
5.3. Gaging the Crimping Chamber
This inspection requires the use of a plug gage
conforming to the diameters in Figure 5. Tyco
Electronics does not manufacture or market these
gages.
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 5.
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 5.
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.
Suggested Plug Gage Design
É
É
É
É
É
É
É
É
É
É
GO
D a NO-GO D a
GO Element Must Pass
Through Cr mp ng Chamber
NO-GO Element Must Not Pass
Through Cr mp ng Chamber
Plat orm
Die
Terminal
Number
Element Diameter
Die
Number
N
um
be
r
(LP) GO NO-GO
90390-3 520081
520084
520273
520182
520194
520275
520184
520264
520103
520129
520335
520337
1.57 [.062] 1.73 [.068]
90391-3 350616
520125
520151
350820
520117
520107
520141
520133
520339
1.83 [.072] 1.98 [.078]
Figure 5

408-9279
Crimping Die Assemblies 90390-3 nd 90391-3
5 of 5Rev B
6. REPLACEMENT AND REPAIR
The parts listed in Figure 6 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
Dies may be returned to Tyco Electronics for
evaluation and repair. For tool repair service, contact
a Tyco Electronics Representative at
1–800–526–5136.
7. REVISION SUMMARY
The following changes were made since the previous
release of this sheet:
S Updated document to corporate requirements
S Deleted portion of artwork in Figure 1
S Changed text in NOTE in Paragraph 3.1.3
S Clarified callout in Figure 3
11
2
BlueRed
Mated
23.11
[.910]
Mated
23.11
[.910]
31.09
[1.224]
31.09
[1.224]
9.47
[.373] 9.47 [.373]
REPLACEMENT PARTS
ITEM NO. PART NUMBER DESCRIPTION QTY PER DIE
1
23-21000-4 21027-3 SCREW, Skt Hd Cap, 10-32 x .375 I . L WRENCH, Hex, .050 I . 1 1
Figure 6