TE Connectivity 58079-3 User manual

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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

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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

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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

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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]
18
1.702-1.709
[.0670-.0673]
1.852-1.854
[.0729-.0730]
58080-3
16
1.829-1.836
[.0720-.0723]
1.979-1.981
[.0779-.0780]
14
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

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REPLACEMENT PARTS
ITEM
PART NUMBER
DESCRIPTION
QTY PER ASSEMBLY
1●
3-21000-4
SCREW, Die Retention
1
2
21027-3
WRENCH, Hex
1
●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]
2
1
57.86
[2.278]
(Mated)
27.05 [1.065]
WEIGHT: 595 g [1.5 oz.]