TE Connectivity 58422-1 User manual

The Tool is Used to Crimp:

AMPLI-BOND* Terminals, PLASTI-GRIP* Terminals,
TERMINYL* Terminals and Splices, Pre-Insulated nylon
HeavyDutyTerminals,Pre-InsulatedAMPOWER*Terminals,
and Sealed COPALUM* Terminals and Splices.
Yoke
Pivot Pin
Piston (Ram)
Cylinder Latch Pin
Dust Cap
Quick-Disconnect
Coupler, Cylinder Half
(Mates With Coupler on
Hose or Handle Control)
©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners.
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Instruction Sheet
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
408-9535

Hydraulic Crimping Heads 
58422-1 and 2161730-1 29 AUG 12 Rev C
Figure 1
1. INTRODUCTION
This instruction sheet provides application,
maintenance, and inspection procedures for Crimping
Heads 58422-1 and 2161730-1 (part number
2161730-1 is a special version of part number 
58422-1, with an extended stroke for terminating
sealed COPALUM quick-termination connectors).
A typical crimping head is shown in Figure 1. The
crimping heads accept interchangeable die sets for a
variety of heavy-duty terminals and splices for large
wire sizes - within Size 8 through 4/0 AWG range.
Refer to instructions packaged with specific die sets
for compatible products, wire ranges, strip dimensions,
and application procedures.
The crimping heads are designed for two 
DYNA-CRIMP* tools: either Hydraulic Hand Pump
314979-1 (covered in customer manual 409-5860) 
or Hydraulic Power Unit 69120-[ ] (described in 
409-1950). Read these instructions, and all applicable
references, before inserting any die assemblies and
crimping any terminals or splices.
NOTE
i
Dimensions on this sheet are in millimeters [with
inches in brackets].


Reasons for reissue are provided in Section 8,
REVISION SUMMARY.
2. DESCRIPTION
Main components of the crimping head are: a yoke
which houses the stationary die and retains the
terminal assembly for crimping, a removable latch pin
which allows pivoting of the yoke on the pivot pin
(typically required for splice terminations), a cylinder
which contains the head's hydraulic chamber, a piston
(ram) which holds and controls the moving die, and a
quick connect/disconnect coupler (cylinder half) which
mates with the coupler on hose or handle control to
release or supply pressure.
DANGER
STOP
To avoid injury when using DYNA-CRIMP
equipment, observe the following precautions:

- Do NOT modify the crimping equipment in 
any way. 
- Use only dies, terminals, and wire specified for 
the head. 
- Do NOT perform repairs other than those
specified in the instructional material supplied

with the equipment.
3. CRIMPING HEAD INSTALLATION
Each crimping head is shipped with a coating of
lubricating oil to prevent rust and corrosion. Wipe the
oil off before installing the crimping head on the power
unit. Note that the crimping head is shipped without oil
inside the cylinder. To install crimping head, proceed
as follows.
DANGER
STOP
Make sure that hydraulic pressure to hose or
handle control is released and that power supply is
disconnected to electric power unit, if applicable.

!
CAUTION
1. Remove protective dust caps from both quick
connect/disconnect couplers.
2. Hold hose or handle control vertically to prevent
oil spillage. Attach hose or handle control to
coupling section on head. Thread properly and
tighten securely.
Oil flow must be unobstructed between power unit
and crimping head. Make sure that all couplers are
fully mated and tightened.


NOTE
i
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2of 4
Rev C
If crimping head must be removed after being in
production, pressure must be released in the
hydraulic system before head is removed.

- If using Hydraulic Power Unit 69120-[ ],
DISCONNECT POWER UNIT FROM

POWER SUPPLY. 
- If using Hydraulic Hand Pump 314979-1,
depress the pressure release.
Yoke
Setscrew
Ram
Setscrew
Ram Advanced
Stationary / Upper Die
Moving / Lower Die
Latch Pin
Removed
Figure 2
4. DIE INSERTION AND REMOVAL (Figure 2)
DANGER
STOP
Avoidpersonal injury. When using power unit,
exercise caution to avoid accidently depressing
foot pedal or handle control when installing or
changing dies.
Make sure that matched die set, terminal, and wire
size are compatible. With crimping head properly
installed, refer to die set instructions, and insert /
change die set as follows:
!
CAUTION
1. Remove latch pin and open yoke on 
crimping head.
2. Loosen setscrew in yoke. Refer to die set
instructions and insert stationary (upper) die which
includes the nest area into well of yoke. Tighten
setscrew.
3. Activate power unit to advance ram until setscrew
is visible (about 12.7 mm [.50 in.]). Loosen
setscrew.
4. Insert moving (lower) die, which serves as the
indenter, into ram well, making sure that moving die
is properly oriented to mate with stationary die.
Tighten setscrew.
5. Close yoke and secure with latch pin.
6. Slowly close dies to ensure proper alignment.
7. Complete the cycle and return the ram to the
DOWN position.
Always ensure that latch pin is fully inserted or
damage may occur to yoke, dies, or latch pin.


5. CRIMPING PROCEDURE
DANGER
STOP
Avoid personal injury. When operating power unit,
exercisecautionwhileholding terminals,splices,or
wire near crimping area.

The following crimping procedure provides general
information. Refer to instructions packaged with
individual die sets for specific products, wire sizes,
strip dimensions, positioning of terminals and splices
in the dies, and crimping procedures.
NOTE
i
Never operate the power unit without having a
crimping head attached to the handle control or
crimping head coupling.

NOTE
i
1. Insert terminal or splice in the stationary (upper)
die according to instructions packaged with the
dies. Make sure the latch pin is secure before
activating the power unit.
2. Slowly advance moving (lower) die with short,
quick strokes until terminal or splice is secure.
3. Insert the stripped wire.
4. Cycle tool to complete crimp. Remove crimped
terminal or splice.
If the splice or terminal sticks in the die after
crimping, apply a rocking action to remove it from
the die.

6. INSPECTION / MAINTENANCE
DANGER
STOP
Make sure hydraulic pressure is released and
power supply is disconnected before following
inspection and maintenance procedures, unless
otherwise specified in the procedure.
Each crimping head is assembled and inspected
before shipment. TE Connectivity recommends that
the crimping head be inspected immediately upon its
arrival at your facility, and at regularly scheduled
intervals, to ensure that the crimping head has not
been damaged during handling. Frequency of
inspection depends upon the following: care, amount
of use, and handling of the head; type and size of
products crimped; degree of operator skill; and
environmental conditions.
6.1. Cleaning
Remove accumulations of dirt and grease on the
crimping head, especially in areas where dies are
installed and terminals are crimped. Clean the entire
head frequently with a clean, lint-free cloth.

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Rev C
6.2. Visual Inspection
Refer to Figure 3 and proceed as follows:
Check Die Areas
for Damage Check These Areas for Cracks
Check for
Excessive
Wear at
Pivot Pin
and Latch
Pin
1. With hydraulic pressure released, inspect the
assembled head for nicks, scratches, and cracks.
Inspect for cracks especially at the corners of the
yoke and around the top of the cylinder.
2. Inspect pivot pin holes and latch pin holes for
wear. Replace parts, as needed.
3. Activate power unit. Raise ram to UP position.
Inspect flat and round surfaces of ram for galling
(fretting or wear by friction), cracks, or oil leakage.
Release pressure and make sure that ram retracts
smoothly.
4. If head shows evidence of galling, cracks, oil
leakage, or rough cycling, return the crimping head
for repairs. (Refer to Section 7, REPLACEMENT
AND REPAIR).
Figure 3
6.3. Crimping Head Check-Out Procedure
If the ram fails to return to the DOWN position after
completion of a crimping cycle, the cause may be in
the crimping head. To determine whether or not the
trouble is in the crimping head, proceed as follows:
A. With Hydraulic Power Unit 69120-()
With power unit activated, press the pressure release
button on the electrical control box. Or, if the unit has
the “dump” feature, move the trigger to the “dump”
position and hold for several seconds. This willrelease
any pressure in the hydraulic system. If the ram
returns to DOWN position, the trouble is NOT in the
crimping head. If ram does not return, ensure that the
coupler is fully engaged. If coupler is engaged and ran
still does not go DOWN, return the crimping head for
repairs.
B. With Hydraulic Hand Pump 314979-1
With power unit activated, turn the hold/return lever to
the RETURN position. If the ram fails to return to the
START or DOWN position, return the crimping head
for repairs.
7. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 4. 
A complete inventory can be stocked and controlled 
to prevent lost time when replacement of parts is
necessary. Order replacement parts through your 
TE representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 1-717-986-7605, or
write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Tools may also be returned to TE for evaluation and
repair. For tool repair service, contact a TE
representative at 1-800-526-5136.
8. REVISION SUMMARY
Since the previous release of this document, the
following changes were made:
•Added Crimping Head 2161730-1 to document.
•Corrected trademark references in Figure 1.
•Updated company name, logo, and format to
corporate requirements.

123.19 [4.850]
76.84
[3.025]
327.32
[12.887]
SECTION A-A
WEIGHT:
12.7 kg [28 lb] (Approx)
A
A
1
2
3
4
5
67
REPLACEMENT PARTS FOR CRIMPING HEADS 58422-1 AND 2161730-1
ITEM PART NUMBER DESCRIPTION QTY PER
HEAD
1311471-1 Coupler, Quick Connect / Disconnect 1
2306209-8 Pin, Removable Latch 1
38-59558-5 Pin, Pivot 1
41-21045-1 Ring, Retaining 1
54-21012-0 Setscrew 3
64-23147-7 Spring, Compression 1
71-21919-6 Pin, Dowel 1
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Rev C
Figure 4