Specific part numbers for die set 58545-[ ] may be
used with other optional crimp tooling. Refer to
Figure 7 for specific relationships.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures and illustrations are for reference only and
are not drawn to scale.
i
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
1
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LOC B
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
ORIGINAL INSTRUCTIONS
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.
408-8678
Stationary Jaw
Indenters
Upper Die
Die Retaining
Screws
Lower Die
Anvils
Figure 2
This document supersedes Instruction Sheet
408-4047.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
6. Carefully close the tool handles, making sure that
the anvils and indenters align properly. Continue
closing the tool handles until the ratchet has
engaged sufficiently to hold the dies in place, then
tighten both die retaining screws.
7. To disassemble, open the tool handles until the
ratchet releases, remove the two die retaining
screws, and slide the dies out of the tool jaws.
2. DESCRIPTION
(See Figures 1 and 2)
The tool consist of a stationary jaw and handle, a
moving jaw and handle, and an adjustable ratchet that
ensures full crimping.
The tool frame holds a die assembly with three
crimping chambers. The die assembly features an
upper die and a lower die. Die retaining screws are
used to position and secure the dies in the tool frame.
4. CRIMPING PROCEDURE
NOTE
i
Before using the tool, the crimping chambers and
tool ratchet should be inspected as specified in
Section 5, CRIMP HEIGHT INSPECTION, and
Section 6, RATCHET (Shut Height) ADJUSTMENT.
3. DIE ASSEMBLY INSTALLATION AND REMOVAL
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the upper die in the stationary jaw of the
tool frame so that the largest indenter is facing
inward. See Figure 2.
3. Insert the die retaining screw through the
stationary jaw and through the die. Tighten the
screw just enough to hold the die in place. Do not
tighten the screw completely at this time.
4. Place the lower die in the moving jaw of the tool
frame so that the largest anvil is facing inward. See
Figure 2.
5. Insert the die retaining screw through the moving
jaw and through the die. Tighten the screw just
enough to hold the die in place. Do not tighten the
screw completely at this time.
Rev
E
Refer to Figure 1 and select wire of the specified size
and insulation diameter. Strip the wire to the length
indicated, taking care not to nick or cut wire strands.
Select an applicable terminal or splice and identify the
appropriate crimping chamber according to the wire
size markings on the dies. Refer to Figure 3 and
proceed as follows:
NOTE
The crimping chamber marked “12-10” cannot be
used to crimp spade-type terminals.
i
1. Hold tool so that the back (wire side) is facing
you. Squeeze tool handles together until the ratchet
releases, then allow them to open fully.
2. Center the terminal or splice wire barrel on the
anvil of the upper die as shown in Figure 3. If
visible, be sure to place the brazed seam on the
terminal or splice toward the indenter.
2
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408-8678
hold the terminal or splice in position. Do NOT
deform the insulation barrel or wire barrel.
4. Insert stripped wire into the wire barrel, making
sure that the insulation does not enter the wire
barrel. See Figure 3.
5. To crimp the other half of a splice, reposition the
uncrimped wire barrel in the crimping chamber, and
repeat the crimping procedure.
Terminal Wire Barrel
Centered on Anvil of
Lower Die
6. To crimp the other half of a splice, reposition the
uncrimped wire barrel in the crimping chamber, and
repeat the crimping procedure.
NOTE
If splice cannot be turned for crimping the other
half, turn the tool around.
Terminal
i
Stripped Wire
7. Inspect the crimped terminal or splice according
to Figure 4. Check the crimp height as described in
Section 5. If necessary, adjust the ratchet (shut
height) as described in Section 6.
Splice
Terminal
Splice Wire Barrel
Centered on Anvil
of Lower Die
Parallel Splice
Butt Splice
Brazed Seam
Positioned Toward
Indenter
Inspection
Hole
Parallel Splice
Splice Wire Barrel
Centered on Anvil
of Lower Die
Figure 3
3. Hold the wire barrel in place and squeeze the tool
handles together until ratchet engages sufficiently to
Rev
E
Figure 4
3
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408-8678
CAUTION
!
Damaged terminals and splices may not be used. If
a damaged terminal or splice is evident, it must be
replaced with a new one.
3. Align the GO element with the crimping chamber.
Push element straight into the crimping chamber
without using force.
NOTE
The GO element must pass completely through the
crimping chamber. See Figure 5.
5. CRIMP HEIGHT INSPECTION
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 5. TE
does not manufacture or market these gages.
To gage the crimping chamber, proceed as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Close the tool handles until the dies have
bottomed. Do NOT force dies beyond initial contact.
i
4. 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 the crimping chamber. See
Figure 5.
If the crimping chamber conforms to the gage
inspection, the tool is considered dimensionally
correct, and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If not, the tool must be
returned to TE for further evaluation and repair. Refer
to Section 8, REPLACEMENT.
For additional information regarding the use of a plug
gage, refer to Instruction Sheet 408-7424.
for 58545-[ ]
6. RATCHET (SHUT HEIGHT) ADJUSTMENT
(Figure 6)
The frame assembly ratchet mechanism features an
adjustment wheel with numbered settings. If the dies
do not bottom, adjust the ratchet as follows:
1. Remove the lockscrew from the ratchet
adjustment wheel.
CRIMPING
CHAMBER
(Die Marking)
22-16
16-14
12-10
GAGE ELEMENT DIMENSIONS
GO
1.143-1.151
[.0450-.0453]
1.346-1.354
[.0530-.0533]
1.905-1.913
[.0750-.0753]
NO-GO
1.344-1.346
[.0529-.0530]
1.547-1.549
[.0609-.0610]
2.106-1.108
[.0829-.0830]
“R” (RADIUS)
1.57 [.062]
1.98 [.078]
2.77 [.109]
2. With a screwdriver, adjust the ratchet wheel from
the opposite side of the frame.
3. Observe the ratchet adjustment wheel. If the dies
do not bottom, rotate the adjustment wheel
COUNTERCLOCKWISE to a higher-numbered
setting.
4. Replace the lockscrew.
Screwdriver
GO Element Must Pass Completely
Through Crimping Chamber
Ratchet Adjustment
Wheel
Lockscrew
NO-GO Element May Start Entry, But Must Not
Pass Completely Through Crimping Chamber
Figure 5
Figure 6
Rev
E
4
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408-8678
7. MAINTENANCE AND INSPECTION
7.1. Maintenance
Ensure that the tool and dies are clean by wiping them
with a clean, soft cloth. Remove any debris with a
clean, soft brush. Do not use objects that could
damage the tool. When not in use, keep handles
closed to prevent objects from becoming lodged in the
crimping dies, and store in a clean, dry area.
replacement nut and a variety of pins, rings, screws,
and springs.
If the dies are damaged or worn excessively, they
must be replaced.
Order the repair kit and replaceable parts through your
TE 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 tool repair service, please contact a TE
Representative at 1-800-526-5136.
7.2. Visual Inspection
The die assembly should be inspected on a regular
basis to ensure that they have not become worn or
damaged. Inspect the crimping chambers for
flattened, chipped, worn, or broken areas. If damage
or abnormal wear is evident, the tool or dies must be
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