Tyco Electronics 408-10205 User manual

Instruction Sheet
SDE Commercial Hand
Tool Assembly 2031676- 1 408--10205
LOC B
1of 5
E2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
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.tycoelectronics.com
07 DEC 09 Rev Bwith Die Assembly 2031676- 2
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.
Handle
Emergency
Ratchet
Release
Die Retention
Screws
Ratchet Adjustment
Wheel
Moving
Jaw
Die Set
2031676--2
Nut Locator
Stationary
Jaw
Anvil (Lower)
Wire Die
Wire Crimper
(Upper Die)
Spacer
Insulation Crimper
(Upper Die)
Anvil (Lower)
Insulation Die
TE Die
A
s
s
e
m
b
l
y
Contacts
Wire Size
(mm2[AWG])
Insulation
(mm [in.])
Assembly
C
o
n
t
a
c
t
s
1.5 [15.5] 1.0 [17] 0.75 [18.5] 0.3--0.6 [22--20] Size Strip Length
183024--1 n n n 1.8--3.3 [.071--.130] 3.0--3.5 [.118--.138]
183025--1 n n n 1.8--3.3 [.071--.130] 3.0--3.5 [.118--.138]
183035--1 n1.4--1.7 [.055--.067] 3.0--3.5 [.118--.138]
2
0
3
1
6
7
6
2
183036--1 n1.4--1.7 [.055--.067] 3.0--3.5 [.118--.138]
2031676--2 282109--1 n n n 1.8--3.3 [.071--.130] 3.0--3.5 [.118--.138]
282110--1 n n n 1.8--3.3 [.071--.130] 3.0--3.5 [.118--.138]
282403--1 n1.4--1.7 [.055--.067] 3.0--3.5 [.118--.138]
282404--1 n1.4--1.7 [.055--.067] 3.0--3.5 [.118--.138]
Refer to Application Specification 114--20045 for Application and Termination Requirements for These Contacts.
Figure 1
1. INTRODUCTION
All dimensions on this instruction sheet are in
metric units [with U.S. customary units in
brackets]. Figures and illustrations are for
identification only and are not drawn to scale.
SDE Commercial Hand Tool Assembly 2031676--1
consists of SDE--SA Frame Assembly 9--1478240--0
(Instruction Sheet 408--8851) and Die Set Assembly
2031676--2. See Figure 1. The tool is used to crimp
contacts shown in Application Specification
114--20045.
2. DESCRIPTION
The tool frame features two jaws, a handle, ratchet
adjustment wheel, and an emergency ratchet release.
The die set consists of an indenter (upper die) and an
anvil (lower die). The tool frame holds a die assembly
with two crimping chambers. See Figure 1. Die
retaining screws are used to secure the dies in the
tool frame.
NOTE
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408- 10205
SDE Commercial Hand Tool Assembly 2031676- 1
Rev B2 of 5 Tyco Electronics Corporation
The tool features a ratchet and an adjustment wheel
with a range of settings. The ratchet ensures that the
tool has completed the cycle and will not release until
the handles have been FULLY closed, unless the
emergency ratchet release is rotated to manually
release the ratchet. The adjustment wheel controls
the amount of handle pressure exerted on the dies
during the crimping procedure.
The dies bottom before the ratchet releases. This
feature ensures maximum tensile performance of
the crimp. DO NOT re--adjust the ratchet.
3. INSTALLATION AND REMOVAL OF DIE SET
AND LOCATOR ASSEMBLY (Figure 1)
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the wire anvil so that the chamfered side
and the marked surfaces face outward, when
mounted in the moving jaw of the tool frame.
3. Insert the short die retaining screw through the
jaw and through the anvil die, and tighten the
screw just enough to hold the die in place. Do not
tighten the screw completely at this time.
4. Place the wire crimper so that the chamfered
side and the marked surface face outward, when
mounted in the stationary jaw of the tool frame.
5. Insert the long die retaining screw through the
jaw and through the crimper die, and tighten the
screw just enough to hold the die in place. Do not
tighten the screw completely at this time.
6. Carefully close the tool handles, making sure
that the anvil and crimper align properly. Continue
closing the tool handles until the ratchet in the tool
frame has engaged sufficiently to hold the anvil
and crimper in place, then tighten both die retaining
screws.
7. Place the locator assembly over the end of the
long screw, and position the locator assembly
against the side of the tool jaw.
8. Place the nut onto the end of the long screw and
tighten the nut enough to hold the locator assembly
in place, while still allowing the locator to slide up
and down.
9. To disassemble, close the tool handles until the
ratchet releases, remove the nut, the locator
assembly, the two die retaining screws, and slide
the anvil and crimper out of the tool jaws.
The ratchet has detents with audible “clicks” as
the handles are closed. The ratchet releases on
the sixth “click”.
4. CONTACT SUPPORT ADJUSTMENT (Figure 2)
The contact support is preset prior to shipment,
but minor adjustment may be necessary.
1. Make a sample crimp and determine if the
contact is straight, bending upward, or bending
downward.
Figure 2
Contact
(Typ)
Strip Length
Wire Inserted
to Stop
Locator in
Wire Stop
Slot
Wire
Adjustment
Screw
for Contact
Support
Contact
Support Locator
Back of Tool
(Wire Side)
CAUTION
!
NOTE
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NOTE
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408- 10205
SDE Commercial Hand Tool Assembly 2031676- 1
3of 5Rev BTyco Electronics Corporation
2. If adjustment is required, loosen the screw that
holds the contact support onto the locator
assembly.
The ratchet has detents that create audible clicks
as the tool handles are closed.
3. Place a contact with wire into the proper nest
and close the tool handles until the ratchet reaches
the sixth click, or until the contact support touches
the contact.
4. Slightly loosen the nut that holds the locator
assembly onto the tool frame.
5. Move the contact support as required to
eliminate the bending of the contact.
6. Tighten the nut and close the handles until the
ratchet releases.
7. Remove and inspect the contact.
8. Make another sample crimp. If the contact is
straight, tighten the contact support screw. If the
contact is still being bent during crimping, repeat
the adjustment procedure.
5. CRIMPING PROCEDURE
This tool is provided with a crimp adjustment
feature. Initially, the crimp height should be
verified as specified in Figure 3. Refer to Section
6, CRIMP HEIGHT INSPECTION, and Section 7,
RATCHET (Crimp Height) ADJUSTMENT, to
verify crimp height before using the tool to crimp
desired contacts and wire sizes.
Refer to the table in Figure 1 and select wire of the
specified size and insulation diameter. Strip the wire
to the length indicated in Figure 1, taking care not to
nick or cut wire strands. Select an applicable contact
and identify the appropriate crimp section according
to the wire size markings on the tool. Refer to
Figure 2 and proceed as follows:
1. Hold the tool so that the back (wire side) is
facing you. Squeeze tool handles together and
allow them to open fully.
2. Holding the contact by the mating end, insert the
contact through the front of the tool and into the
appropriate crimp section.
3. Position the contact so that the mating end of
the contact is on the locator side of the tool, and so
that the open “U” of the wire barrel faces the top of
the tool. Place the contact up into the nest so that
the movable locator drops into the slot in the
contact. Refer to Figure 2. Butt the front end of the
wire barrel against the movable locator.
Position Point on
Center of Wire
Barrel Opposite
Seam
Modified Anvil
“A”
Wire Size
(Max) mm2Crimp Section (Wire Size Markings)
Crimp Height
Dimension “A”
1.5 1.5 1.52 +0.05 [.060 +.002]
1.0 1.0 1.37 +0.05 [.054 +.002]
0.75 0.75 1.29 +0.05 [.051 +.002]
0.50 0.35--0.50 0.99 +0.05 [.039 +.002]
Figure 3
Make sure that both sides of the wire barrel are
started evenly into the crimping section. Do NOT
attempt to crimp an improperly positioned
contact.
6. CRIMP HEIGHT INSPECTION
Crimp height inspection is performed through the use
of a micrometer with a modified anvil, commonly
referred to as a crimp--height comparator. Tyco
Electronics does not manufacture or market
crimp--height comparators. Detailed information on
obtaining and using crimp--height comparators can be
found in instruction sheet 408--7424.
Proceed as follows:
1. Refer to Figure 3 and select a wire (maximum
size) for each crimp section listed.
2. Refer to Section 5, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
3. Using a crimp height comparator, measure the
wire barrel crimp height as shown in Figure 4. If the
crimp height conforms to that shown in the table,
the tool is considered dimensionally correct. If not,
the tool must be adjusted. Refer to Section 7,
RATCHET (Crimp Height) ADJUSTMENT.
7. RATCHET (Crimp Height) ADJUSTMENT
Although the ratchet is preset prior to shipment, it is
important to verify the crimp height using a
micrometer or caliper. General use and subsequent
wear may cause the tool to go out of adjustment. It is
recommended that crimp height be inspected, and the
ratchet be adjusted, if necessary, on a regular basis.
Refer to Figure 4, and proceed as follows:
NOTE
i
NOTE
i
CAUTION
!

408- 10205
SDE Commercial Hand Tool Assembly 2031676- 1
Rev B4 of 5 Tyco Electronics Corporation
Figure 4
Ratchet Adjustment Wheel
Adjustment
Screw
1. If the crimp height is larger than recommended,
remove the ratchet wheel adjustment screw and
rotate the adjustment wheel counterclockwise (+)
to a higher setting. Reinstall the screw. Repeat as
required.
2. If the crimp height is smaller than
recommended, remove the ratchet wheel
adjustment screw and rotate the adjustment wheel
clockwise (--) to a lower setting. Reinstall the
screw. Repeat as required.
3. If the crimp cannot be made to conform to the
recommended crimp height, the tool or die set
must be replaced. See Section 9,
REPLACEMENT.
8. MAINTENANCE AND INSPECTION
8.1. Daily Maintenance
1. Remove dust, moisture, and other contaminants
with a clean, soft brush, or a clean, soft, lint--free
cloth. DO NOT use any objects that could damage
the dies or tool.
2. Make sure that the proper die retaining screws
are properly secured.
3. When the tool is not in use, keep the handles
closed to prevent objects from becoming lodged in
the dies. Store the tool in a clean, dry area.
4. Remove all lubrication and accumulated film
from the dies by immersing the dies in a suitable
commercial degreaser.
8.2. Inspection
Close the tool handles until the ratchet releases, and
then allow them to quickly open freely. If they do not
open quickly and fully, the spring is defective. See
Section 9, REPLACEMENT.
9. REPLACEMENT
Order replacements through your representative, or
call 1--800--526--5142, or send a facsimile of your
purchase order to 717--986--7605, or write to:
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
10. REVISION SUMMARY
SRemoved contacts from the table in Figure 1;
SUpdated format to current corporate
requirements.

408- 10205
SDE Commercial Hand Tool Assembly 2031676- 1
5of 5Rev BTyco Electronics Corporation
Figure 5
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(Instruction Sheet 408-9930) SDE- SA Hand Tool 9- 1478240-0
(Instruction Sheet 408-8851)
SDE Bench Terminator 1490076-2
(Customer Manual 409- 10052)
626 Adapter 679304- 1
(Instruction Sheet 408-4070)
Battery Tool (Shouldered Die) 1725837- 1, -2
(Customer Manual 409- 10053)
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(Customer Manual 409- 10065)
1976754-2 Die Set can be Used in Tools Show Below