TE Connectivity 58079-3 User manual

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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.

Instruction Sheet

408-9278

21 AUG 15 Rev C

Figure 1

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.

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 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 platform.

When mated, the dies form two crimping chambers, each marked with the wire size range.

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.

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 already installed in the lower jaw platform. See Figure 3.

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. The setscrew must be flush on both sides.

3. Using hex wrench, turn socket head setscrew CLOCKWISE until snug. Do NOT over-tighten.

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

58079-3 and 58080-3

Upper Die

(Crimper)

Die Retention

Screw

Wire Size

Range Markings

Color Dot Code

Crimping

Chamber

Wire Size Range Markings

Lower Die (Anvil)

Hex Wrench

Access Hole

ORIGINAL INSTRUCTIONS

408-9278

Rev C

2 of 5

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

ULTRA-FAST PLUS TERMINALS

DIE ASSEMBLY

SIZE (AWG)

INSUL DIA (MAX)

SERIES

PART NO.

COLOR CODE DOT

PART NO.

22-18

3.43 [.135]

.187

2-520409-2

Red

58079-3

2-520411-2

.250

2-520407-2

16-14

4.06 [.160]

.187

3-520410-2

Blue

58080-3

3-520412-2

.250

3-520408-2

Figure 2

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.

Figure 3

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.

Die Retention Screw

Mounting Hole

Back Side of

Tool Frame (Ref)

Upper Jaw Platform

Socket Head

Setscrew Must be

Flush on Both Sides

Die Assembly

Upper Die

Color Dot Code

Lower Die

Color Dot Code

Hex Wrench

Access Hole Must

Align with Setscrew

Lower Jaw

Platform

408-9278

Rev C

3 of 5

Figure 4

3. Push the locator assembly away from the upper crimping die slightly and hold.

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.

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.

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:

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.

Insulation Barrel

Wire Barrel

Strip Length

7.14 [.281]

Front Side of

Tool Frame (Ref)

Locator Stop

Flat Side of

Terminal

Mating End

of Terminal

Locator

Crimping

Chamber

408-9278

Rev C

4 of 5

Figure 5

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:

1. Remove traces of oil or dirt from the crimping chambers and plug gage.

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.

6. REPLACEMENT AND REPAIR

Customer-replaceable parts are listed in Figure 6. Parts other than those listed should be replaced by TE to

ensure quality and reliability. For customer repair service or to order replacement parts, call 1-800-522-6752, or

fax your purchase order to 717-986-7605, or write to:

Customer Service (038-035),

Tyco Electronics Corporation

PO Box 3608

Harrisburg, PA 17105-3608.

7. REVISION SUMMARY

Updated document to corporate requirements

Added new callouts to Figures 1 and 3

Added new text to Paragraph 3.1 and NOTE in 3.1

Added new information to table in Figure 6

NO-GO element may

enter partially, but must

not pass completely

through the die closure.

DIE ASSEMBLY

ELEMENT DIAMETER

PART

NO.

WIRE SIZE

MARKING

GO NO-GO

58079-3

22-20

1.575-1.582

[.0620-.0623]

1.725-1.727

[.0679-.0680]

1.702-1.709

[.0670-.0673]

1.852-1.854

[.0729-.0730]

58080-3

1.829-1.836

[.0720-.0723]

1.979-1.981

[.0779-.0780]

1.956-1.963

[.0770-.0773]

2.106-1.108

[.0829-.0830]

Suggested Plug Gage Design

GO Dim.

NO-GO Dim.

Crimping

Chamber

Go element must pass

completely through the

die closure.

GO Element

NO-GO Element

408-9278

Rev C

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REPLACEMENT PARTS

ITEM

PART NUMBER

DESCRIPTION

QTY PER ASSEMBLY

1●

3-21000-4

SCREW, Die Retention

21027-3

WRENCH, Hex

●A hex head setscrew is already installed in the hand tool lower jaw platform. This setscrew is a spare part.

Figure 6

Color Dot Code:

Die Assembly 58079-3 (Red)

Die Assembly 58080-3 (Blue)

15.82 [.623]

57.86

[2.278]

(Mated)

27.05 [1.065]

WEIGHT: 595 g [1.5 oz.]

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