Instruction Sheet Crimping Die Assemblies 408-9278 58079-3 and 58080-3 21 AUG 15 Rev C 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. Upper Die Die Retention (Crimper) Screw Wire Size Range Markings Crimping Chamber Color Dot Code Hex Wrench Access Hole Lower Die (Anvil) Wire Size Range Markings 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. 2015 TE Connectivity family of companies PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. 1 of 5 All Rights Reserved For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. 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 408-9278 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. 2-520409-2 .187 22-18 3.43 .135 2-520411-2 Red 58079-3 .250 2-520407-2 3-520410-2 .187 16-14 4.06 .160 3-520412-2 Blue 58080-3 .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. Back Side of Die Retention Screw Tool Frame (Ref) Mounting Hole Upper Jaw Platform Socket Head Setscrew Must be Flush on Both Sides Die Assembly Upper Die Color Dot Code Lower Jaw Hex Wrench Lower Die Platform Access Hole Must Color Dot Code Align with Setscrew 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. 2 of 5 Rev C