? 2011 tyco electronics corporation, a te connectivity ltd. company ? all rights reserved *trademark te connectivity, te connectivit y (logo), and te (logo) are trademarks. other logos, product and/or company names may be tradem arks of their respective owners. 1 of 4 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 loc b 408-9227 application and maintenance for ? crimping die assemblies ? 58268-1 and 58268-2 08 dec 11 rev c figure 1 die holding screw wire size marking die assembly part number markings die holding screw stationary dies (anvils) crimping chamber terminal type markings moving dies (crimpers) 1. introduction crimping die assemblies 58268-1 and 58268-2 are designed for use in the auto-pro* machine 818380-1 equipped with applicator 818058-2. each die assembly, when installe d in the machine, will crimp ultra-fast plus fully insulated faston* terminals 520401-[ ] onto wire sizes no. 22-18 awg (die assembly -1) and terminals 520402-[ ] onto wire sizes no. 16-14 awg (die assembly -2). these instructions provid e s pecific information regarding the die assemblies and applicable terminals. for general performance of the machine, refer to 408- 9491, packaged with the machine. for specific information on the applicator, refer to 408-8092. dimensions in this instruction sheet are in metric units [with u.s. customary units in brackets]. figures are not drawn to scale. note i reasons for reissue are provided in section 7, revision summary. 2. description each die assembly consists of two stationary dies (anvils) and two moving dies (crimpers) which when closed form the crimping chamber. the stationary dies feature a die holding screw and have the die assembly part number marking. the moving dies also feature a die holding screw and have the die assembly part number, specific wire size, and terminal type markings. see figure 1. the translucent color of the insulation on the terminal ind icates a specific wire range and must match the wire size marking on the die assembly for crimping. refer to figure 2. wire barrel wire strip length 3.96 [.156] note: not to scale wire terminal crimping di e assy part number size (a wg) insulation dia (max) part numb er color 22-18 3.43 [.135] 520401-[ ] red 58268-1 16-14 4.06 [.160] 520402-[ ] blue 58268-2 figure 2 3. die installation and removal the anvils and crimpers can be installed and removed from the machine by tightening or loosening the die holding screws. refer to 408-8092 for specific instructions on die in stallation and removal. danger stop to avoid personal inju ry, always disconnect electrical and air suppl y before installing or removing dies. close lockout valve and apply lock to prevent accidental cycling of machine.
408-9227 2 of 4 rev c 4. crimping procedure refer to figure 2 and select a terminal for the wire of the specified size. strip the wire to the length indicated, taking care no t to cut or nick the wire strands. make sure the die assembly is compatible with the terminal being used. position the terminal in the die assembly as instructed in 408-8092 and follow the specific instructions for crimping .187 series ultra-fast plus terminals. 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 no. 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 rema ining with the dies and/or supervisory personnel responsible for them. ? te connectivity recommends one inspection per mo nth; however, amount of use, working conditions, operator training and skill, and est ablished company standards should determine frequency of inspection. the inspection should be performed in the following sequence: 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 all die hold ing screws, retaining rings, and die components are in place and secured. refer to section 6, r eplacement and repair, if replacements are necessary. 3. check all bearing surfaces for wear. replace wor n components. 4. inspect the crimping chamber for flattened, chip ped, 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. b. gaging the crimping chamber this inspection requires the use of a plug gage conforming to the dimensions in figure 3. te does not manufacture or market these gages. to gage the crimping chamber, proceed as follows: 1. remove traces of oil or dirt from crimping cha mber and plug gage. 2. mate the dies until it is e vident that the dies have bottomed, then hold in th is position. do not force the dies beyond initial contact. 3. align the go element with the crimping chamber. push ele ment straight into the crimping chamber without using force. the go element must pass completely through. refer to figure 3. note i insert insulation plug gage in the crimping chamber from the front si de of the die asse mbly and insert wire barrel plug gage in the back side of the die assembly. 4. now align the no-go elem ent 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 3. if the crimping chamber conforms to the gage insp ection, the die assembly is considered dimensionally correct and should be lubricated with a thin coat of any good sae no . 20 motor oil. if not, the die assembly must be repaired before returning it to service. see secti on 6, replacement and repair. for additional information concerning the use of the plu g gage, refer to instruction sheet 408-7424. 6. replacement and repair replacement parts or recommended spares are listed in figure 4. the recommended spares should be stocked for immediate replacement. order replacement parts through your te representative or call 1-800-526-5142, or write to: customer service (038-035) ? tyco electronics corporation ? po box 3608 ? harrisburg pa 17105-3608 7. revision summary since the previous version of this document, the following changes were made: ? updated document to corporate requirements.
suggested plug gage design for insulation barrel crimp suggested plug gage design for wire barrel crimp ?f? dim. go dim. no-go dim. crimping chamber go element must pass completely through the crimping chamber no-go element may enter partially, but must not pass completely through the crimping chamber no-go element may enter partially, but must not pass completely through the crimping chamber go element must pass completely through the crimping chamber crimping chamber crimping chamber no-go dim. go dim. die assembly part number gage element dimensions insulation barrel crimp wire barrel crimp ?f? dim. go no-go go no-go 58268-1 1.473-1.491 [ 0.0580-0.0587] 1.829-1.847 [0.0720- 0.0727] 1.872-1.880 [0.0737- 0.0740] 1.981-1.989 [0.0780- 0.0783] 4.32 [0.170] 58268-2 1.829-1.847 [ 0.0720-0.0727] 2.184-2.202 [0.0860- 0.0867] 2.024-2.032 [0.0797- 0.0800] 2.134-2.141 [0.0840- 0.0843] 408-9227 3 of 4 rev c figure 3
15.82 [.623] 57.86 [2.278] 27.05 [1.065] weight: 595 g [1.5 oz] 1 10 2 3 4 5 6 7 8 9 replacement parts item part numer description qty per assembly die assembly 58268-1 die assembly 58268-2 1 1-59781-4 screw, die holding 2 2 2 1-21046-3 ring, retaining 2 2 3 313355-1 crimper, wire 1 - - 4 313357-1 crimper, insulation 1 - - 5 313356-1 anvil, wire 1 - - 6 313358-1 anvil, insulation 1 - - 7 313355-2 crimper, wire - - 1 8 313357-2 crimper, insulation - - 1 9 313356-2 anvil, wire - - 1 10 313358-2 anvil, insulation - - 1 408-9227 4 of 4 rev c figure 4
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