The die assemblies are identified by the part number,
color dot code, and applicable wire range markings.
Refer to Figure 2. The color dot code on the die
assembly must match the color--coded terminal.
Wire Size
Range
Markings
Color
Dot
Code
Crimping
Chamber
Wire Size Range
Markings
Figure 1
3. DIE ASSEMBLY INSTALLATION
3.1. Installing Lower Die
1. Close tool frame handles until ratchet releases,
then allow handles to open FULLY.
2. Slide lower die onto lower jaw platform of tool
frame. Make sure that the hole on the side of the
lower die aligns with the socket head setscrew on
the platform. See Figure 3.
Lower Die
(Anvil)
NOTE
If lower die will not position properly, use hex
wrench provided with die assembly to turn
socket head setscrew either in or out until lower
die positions properly.
i
1. INTRODUCTION
This instruction sheet covers application and
maintenance procedures for Crimping Die Assemblies
58079--3 and 58080--3. See Figure 1. Each die
assembly is used with Hand Crimping Tool Frame
58078--3, which will crimp the Ultra--Fast Plus Fully
Insulated FASTON* Terminals listed in Figure 2.
Refer to Instruction Sheet 408--6976 (supplied with
tool frame) for specific tooling information. Product
part number information is available in Catalog 82004.
NOTE
Dimensions are in millimeters [with inch
equivalents in brackets]. Figures are for
identification only and are not drawn to scale.
3. Using hex wrench, turn socket head setscrew
CLOCKWISE until snug. Do NOT overtighten.
3.2. Installing Upper Die
1. Remove die retention screw from upper die.
2. Slide upper die onto upper jaw platform of tool
frame. Make sure the color dot code on upper die
is on the same side as the color dot code on lower
die. See Figure 3.
WIRE
SIZE
(AWG)
ULTRA-- FAST PLUS
TERMINALS
PART NO.
2--520409--2
2--520411--2
2--520407--2
3--520410--2
3--520412--2
3--520408--2
Figure 2
Blue
58080--3
Red
58079--3
DIE ASSEMBLY
COLOR
CODE
DOT
PART NO.
i
INSUL
DIA. SERIES
(MAX)
3 43
3.43
[.135]
.187
187
.250
.187
187
.250
Reasons for reissue are provided in Section 7,
REVISION SUMMARY.
22--18
2. DESCRIPTION
Each die assembly consists of an upper die (crimper)
and a lower die (anvil), a die retention screw (on
upper die), and a hex wrench for securing the socket
head setscrew to the lower die and onto the hand tool
E2011
Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
16--14
4 06
4.06
[.160]
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
of 4
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- 9278
Die Retention Screw
Back Side of
Tool Frame
(Ref)
Mounting Hole
Upper Jaw Platform
Socket Head
Setscrew
Die Assembly
Upper Die
Color Dot
Code
Lower Jaw
Platform
Hole Must Align
with Setscrew
Figure 3
Lower Die
Color Dot
Code
3. Insert die retention screw through mounting hole
in top of tool frame and thread, but do not tighten,
the screw.
4. Carefully close the tool handles, making sure
that the dies align properly.
5. Tighten the die retention screw until secure.
4. Insert terminal mating end, flat side facing
locator, in the BACK side of the tool frame; center
on the appropriate crimping chamber on the lower
crimping die. Allow terminal to butt against locator
stop. See Figure 4.
5. Holding terminal in position, release locator
assembly. Insert stripped wire into wire barrel until
wire bottoms.
6. Hold wire in position and maintain light pressure.
Then, squeeze tool frame handles together until
ratchet releases.
7. Allow tool frame handles to open FULLY.
Holding locator assembly in position, remove
crimped terminal.
4. CRIMPING PROCEDURE
Select the appropriate wire size and terminal for the
die assembly. The wire size and insulation diameter
must be within a specified range for the terminal. Strip
the wire to the appropriate length shown in Figure 4.
Do NOT cut or nick the wire strands. Then, proceed
as follows:
1. Hold tool frame so that the FRONT side is
facing you and open crimping dies by squeezing
tool frame handles together until ratchet releases.
2. The locator stop must be adjusted to
accommodate the terminal series size, which is
marked on the terminal insulation (.187 or .250).
Rotate the blue plastic locator stop until the series
size number, appearing in the uppermost position,
matches the terminal series size. Refer to Figure 4.
3. Push the locator assembly away from the upper
crimping die slightly and hold.
5. MAINTENANCE AND INSPECTION
5.1. Maintenance
1. Remove dust, moisture and other contaminants
with a clean brush, or a soft, lint--free cloth. Do not
use objects that could damage the dies.
2. Make certain that all surfaces are protected with
a thin coat of any good SAE 20 motor oil. Do not
oil excessively.
3. When dies are not in use, store in a clean, dry
area.
2
of 4
Rev B
408- 9278
Insulation Barrel
Wire Barrel
Front Side of
Tool Frame (Ref)
Locator Stop
Strip Length
7.14 [.281]
Flat Side of
Terminal
Mating End
of Terminal
NOTE:
Not to Scale
Locator
Figure 4
Crimping Chamber
5.2. Periodic Inspection
Regular inspections should be performed with a
record of inspections remaining with the dies and/or
supervisory personnel responsible for them. TE
Connectivity recommends one inspection per month;
however, amount of use, working conditions, operator
training and skill, and established company standards
should determine frequency of inspection. The
inspection should be performed in the following
sequence:
1. Remove traces of oil or dirt from the crimping
chambers and plug gage.
GO DIM.
Suggested Plug Gage Design
NO--GO DIM.
Crimping
Chamber
A. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable commercial
degreaser that will not affect paint or plastic
material.
2. Make sure the die retention screw and die
components are in place and secured. Refer to
Section 6, REPLACEMENT AND REPAIR, if
replacements are necessary.
3. Check all bearing surfaces for wear. Replace
worn components.
4. Inspect the crimping chambers for flattened,
chipped, cracked, worn, or broken areas. If
damage is evident, the dies must be repaired
before returning them to service. See Section 6,
REPLACEMENT AND REPAIR.
GO Element
GO element must pass
completely through the
die closure.
DIE ASSEMBLY
WIRE SIZE
PART NO.
MARKING
22--20
58079--3
18
16
58080--3
14
NO-- GO Element
NO--GO element may enter
partially, but must not pass
completely through the
die closure.
ELEMENT DIAMETER
GO
1.575--1.582
[.0620--.0623]
1.702--1.709
[.0670--.0673]
1.829--1.836
[.0720--.0723]
1.956--1.963
[.0770--.0773]
Figure 5
NO-- GO
1.725--1.727
[.0679--.0680]
1.852--1.854
[.0729--.0730]
1.979--1.981
[.0779--.0780]
2.106--2.108
[.0829--.0830]
B. Gaging the Crimping Chamber
This inspection requires the use of a plug gage
conforming to the diameters in Figure 5. TE does not
manufacture or market these gages. To gage the
crimping chambers, proceed as follows:
Rev B
3
of 4
408- 9278
2. Mate the dies until it is evident that the dies
have bottomed, then HOLD in this position. Do
NOT force the dies beyond initial contact.
3. Align the GO element with the crimping
chamber. Push element straight into the crimping
chamber without using force. The GO element
must pass completely through. Refer to Figure 5.
4. 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 5.
If the crimping chambers conform to the gage
inspection, the die assembly is considered
dimensionally correct and should be lubricated with a
THIN coat of any good SAE 20 motor oil. If not, the
die assembly must be repaired before returning it to
service. See Section 6, REPLACEMENT AND
REPAIR.
For additional information concerning the use of the
plug gage, refer to Instruction Sheet 408--7424.
15.82
[.623]
6. REPLACEMENT AND REPAIR
Replacement parts or recommended spares are listed
in Figure 6. The recommended spares should be
stocked for immediate replacement. Order
replacement parts through your TE Representative or
call 1--800--526--5142, or send a facsimile of your
京公网安备 11010802033920号
EEWORLD
