Instruction Sheet
Application and Maintenance for
Crimping Die Assemblies
58268-1 and 58268-2
Moving Dies
(Crimpers)
Die Holding
Screw
Wire Size
Marking
408-9227
08 DEC 11 Rev C
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
indicates a specific wire range and must match the
wire size marking on the die assembly for crimping.
Refer to Figure 2.
Terminal Type
Markings
Die Assembly
Part Number
Markings
Wire
Barrel
Crimping
Chamber
Wire Strip
Length
3.96 [.156]
Stationary Dies
(Anvils)
Die Holding
Screw
NOTE: Not to Scale
WIRE
TERMINAL
CRIMPING
DIE ASSY
PART
NUMBER
SIZE
(AWG)
INSULATION
DIA (Max)
PART
NUMBER
COLOR
1. INTRODUCTION
22-18
3.43 [.135]
520401-[ ]
Red
58268-1
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 installed 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).
16-14
4.06 [.160]
520402-[ ]
Blue
58268-2
Figure 1
These instructions provide specific information
regarding the die assemblies and applicable terminals.
For general performance of the machine, refer to 4089491, packaged with the machine. For specific
information on the applicator, refer to 408-8092.
NOTE
i
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 installation and removal.
DANGER To avoid personal injury, always disconnect
electrical and air supply before installing or
STOP
removing dies. Close lockout valve and apply lock
to prevent accidental cycling of machine.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
Reasons for reissue are provided in Section 7,
REVISION SUMMARY.
© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
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
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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LOC B
408-9227
4. CRIMPING PROCEDURE
B. Gaging the Crimping Chamber
Refer to Figure 2 and select a terminal for the wire of
the specified size. Strip the wire to the length
indicated, taking care not to cut or nick the wire
strands. Make sure the die assembly is compatible
with the terminal being used.
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:
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 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:
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 holding screws, retaining rings,
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 chamber 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.
Rev C
1. Remove traces of oil or dirt from crimping
chamber 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 3.
NOTE
i
Insert INSULATION plug gage in the crimping
chamber from the FRONT side of the die assembly
and insert WIRE BARREL plug gage in the BACK
side of the die assembly.
4. Now align the NO-GO element and try to insert it
straight into the same crimping chamber. The NOGO element may start entry but must not pass
completely through as shown in Figure 3.
If the crimping chamber conforms to the gage
inspection, 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 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
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.
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408-9227
SUGGESTED PLUG GAGE DESIGN FOR
INSULATION BARREL CRIMP
Crimping
Chamber
“F”
Dim.
NO-GO
Dim.
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
Crimping
Chamber
SUGGESTED PLUG GAGE DESIGN FOR
WIRE BARREL CRIMP
NO-GO
Dim.
GO
Dim.
GO Element Must Pass
Completely Through the
Crimping Chamber
DIE ASSEMBLY
PART NUMBER
NO-GO Element May Enter
Partially, But Must Not Pass
Completely Through the
Crimping Chamber
GAGE ELEMENT DIMENSIONS
INSULATION BARREL CRIMP
WIRE BARREL CRIMP
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]
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]
“F” DIM.
4.32
[0.170]
Figure 3
Rev C
3 of 4
408-9227
27.05
[1.065]
15.82
[.623]
3 7
2
1
57.86
[2.278]
4 8
5 9
6 10
WEIGHT: 595 g [1.5 oz]
REPLACEMENT PARTS
ITEM
PART NUMER
1
1-59781-4
2
DESCRIPTION
QTY PER ASSEMBLY
DIE ASSEMBLY 58268-1
DIE ASSEMBLY 58268-2
SCREW, Die Holding
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
Figure 4
Rev C
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