Tyco Electronics SDE-SA 2063526 Series User manual

©2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
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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.tycoelectronics.com
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LOC B
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use a
low volume applications. A wide selection of powered application equipment for extended-use, production operations is available.
Figure 1
1. INTRODUCTION
SDE-SA Hand Crimping Tool Assembly 2063526-1
consists of SDE-SA Frame Assembly 9-1478240-0
and die set assembly 2063526-2. See Figure 1. The
tool is used to crimp MCP 2.8K Contact system. Refer
to 114-18387 for contact application.
Dimensions in this instruction sheet are in
millimeters. Figures and illustrations are for
reference only and are not drawn to scale.
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 pins and die retaining screws are used to
position and secure the dies in the tool frame.
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
1. Open the tool handles and remove the two die
retaining screws from the tool jaws.
2. Place the wire anvil and insulation anvil so that
their chamfered sides and their marked surfaces
TE Die Assembly Contacts Wire Size (mm2)Insulation Diameter
(mm) Strip Length
2063526-2
1241397-[ ]
2.50 2.70 - 3.00
4.5 ± 0.3
1.50 2.20 - 2.40
1241395-[ ] 0.50-1.0 1.40 - 2.10 4.0 ± 0.3
1241393-[ ] 0.20- 0.35 1.15 - 1.40 3.7 ± 0.3
Nut
Nut
Wire Crimper
(Upper Die) Die Retention
Screws
Emergency Ratchet Release
Retaining Pins
(4) Required
Anvil (Lower) Insulation Die
Anvil (Lower) Wire Die
Contact
Die Set 2063526-2
Insulation Crimper
(Upper Die) Stationary
Jaw
Moving Jaw
Ratchet
Adjustment
Wheel
Locator
Handle
Support
NOTE
i
NOTE
i
SDE-SA Hand Crimping Tool
Assembly 2063526-[ ] with
Die Assembly 2063526-2 408-10375
23 JUN 10 Rev A

408-10375
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Tyco Electronics Corporation
Rev A
face outward, when mounted in the moving jaw
of the tool frame.
3. Insert the two die retaining pins.
4. Insert the short die retaining screw through
the jaw and through both anvil dies, and tighten
the screw just enough to hold the dies in place.
Do not tighten the screw completely at this time.
5. Place the wire crimper and insulation crimper
so that their chamfered sides and their marked
surfaces face outward, when mounted in the
stationary jaw of the tool frame.
6. Insert the two die retaining pins.
7. Insert the long die retaining screw through the
jaw and through both crimper dies, and tighten
the screw just enough to hold the dies in place.
Do not tighten the screw completely at this time.
8. Carefully close the tool handles, making sure
that the anvils and crimpers align properly.
Continue closing the tool handles until the
ratchet in the tool frame has engaged sufficiently
to hold the anvils and crimpers in place, then
tighten both die retaining screws.
9. Place the locator assembly over the end of the
long screw, and position the locator assembly
against the side of the tool jaw.
10. 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.
11. To disassemble, close the tool handles until
the ratchet releases, remove the nut, the locator
assembly, the two die retaining screws, and the
four die retaining pins, and slide the anvils and
crimpers 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
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.
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.
Figure 2
NOTE
i
NOTE
i
NOTE
i
Contact Support Locator
Back of Tool
(Wire Side)
Wire
Contact
(Typ) Strip Length
Wire
Inserted to
Stop:
L o c a t o r i n
Wire Stop
S l o t
Adjustment Screw
for Contact Support

408-10375
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Tyco Electronics Corporation
Rev A
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 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 — insulation barrel first — 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 and insulation
barrels must face 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.
Make sure that both sides of the insulation 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 1 and select a wire (maximum
size) for each crimp section listed, then crimp
the contacts accordingly.
2. Using a crimp height comparator, measure the
wire barrel crimp height listed in Figure 3. 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 ADJUSTMENT. Seam
Figure 3
Damaged product should not be used. If a
damaged contact is evident, it should bereplaced.
Contacts must not be re--terminated.
7. CRIMP HEIGHT (RATCHET) 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:
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.
NOTE
NOTE
i
CAUTION
!
Wire Size
mm2 (Max)
Crimp Section
(Wire Size
Markings)
Crimp Height
Dimension “A” and
Tolerance (+)
2.5] 2.5 1.88 ± 0.05 [.074±.002]
1.5 1.5 1.58 ± 0.05 [.062±.002]
1.0 0.5-1.0 1.23 ± 0.05 [.048±.002]
.35 0.2-0.35 0.98 ± 0.05 [.038±.002]
CAUTION
!
Position Point on
Center of Wire Barrel
Opposite Seam
Modified
Anvil

408-10375
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Tyco Electronics Corporation
Rev A
Figure 4
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
1. 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.
2. Inspect the crimping surfaces of the dies for
flattened, chipped, worn, or cracked areas. If
damage is evident, the dies must be replaced.
Refer to Section 9, REPLACEMENT.
9. REPLACEMENT
Order replacement parts through your local Tyco
Electronics 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
New release of 408-10375
Adjustment
Screw
Ratchet Adjustment Wheel

408-10375
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Tyco Electronics Corporation
Rev A
Die Set 2063526-2 Can be Used in the Tools Shown Below: