Tyco Electronics SDE- SA User manual

Instruction Sheet
SDE- SA Commercial Hand Tool for 408--10309
LOC B
1of 4
E2010 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
26 JAN 10 Rev DUTILUX* Connectors
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 Retaining
Screws
Ratchet Adjustment
Wheel
Moving
Jaw
Die Sets
2063195--2,
1976147--2
Stationary
Jaw
Anvil (Lower)
Wire Die
Wire Crimper
(Upper Die)
Insulation Crimper
(Upper Die)
Anvil (Lower)
Insulation Die
Pins (4)
Locator
Locking Nut
TE Crimp Tooling
U
T
I
L
U
X
Cable Wire Insulation
SDE--SA
Tool
Die
Assembly
U
T
I
L
U
X
Connector Qty Cable Type
mm [Inch]
Conductor
Size
Dia
mm [Inch]
Strip Length
mm [Inch}
2063765--1 2063765--2
1--659268--0
1
Olex Railway
Cable{
2008--01--12(L)
.75mm2[18]
Doubled Over 3.5mm [.138]
10.0mm [.39]
Conductor
Doubled Over
1976147--1 1976147--2
1
6
5
9
2
6
8
0
2Advance Railway
Cable}.75mm2[18] 2.4mm [.094] 5.0mm [.197]
Figure 1
1. INTRODUCTION
SDE--SA Commercial Hand Tool Assemblies for the
UTILUX connectors consist of the tools and die sets
shown in Figure 1. The tools consist of the of
SDE--SA Frame Assembly 9--1478240--0 (Instruction
Sheet 408--8851) and die assemblies listed in
Figure 1. The tool is used to crimp the terminal
number provided in the table in Figure 1.
Dimensions in this instruction sheet are in
millimeters with [inches in brackets]. Figures and
illustrations are for reference only and are not
drawn to scale.
Reasons for revison are provided in Section 9,
REVISION SUMMARY.
Read these instructions thoroughly before crimping
connectors.
}Advance Wire and Cable Pty Ltd{Olex Nexans Company.
NOTE
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408- 10309
SDE- SA Commercial Hand Tool Assembly for UTILUX Connectors
Rev D2 of 4 Tyco Electronics Corporation
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.
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 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 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 nut onto the end of the long screw and
tighten the nut enough to hold the locator assembly
in place.
8. To disassemble, close the tool handles until the
ratchet releases, remove the nut, locator assembly,
the four 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. 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 5, CRIMP HEIGHT INSPECTION, and
Section 6, 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.
Figure 2
Insert Wire
Here
Back of Tool
(Wire Side)
Locator
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.
CAUTION
!
NOTE
i
NOTE
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408- 10309
SDE- SA Commercial Hand Tool Assembly for UTILUX Connectors
3of 4Rev DTyco Electronics Corporation
Position Point on
Center of Wire
Barrel Opposite
Seam
Modified Anvil
“A”
TE Tooling
Wire Size
Max
mm2[AWG]
Crimp Section
(Wire Size
Markings)
Crimp Height
Dimension
“A”
2063765--[ ] 0.75
[18] 0.75 1.45 + 0.50
1976147--[ ] 2--0.75
[2 -- # 18] 2 X 0.75
1
.
4
5
+
0
.
5
0
[.057 + .002]
Figure 3
3. Position the contact 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 wire barrel is
against the locator. See Figure centered on the
wire crimper.
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.
5. 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.
2. Refer to Section 4, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
3. 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 6,
RATCHET (Crimp Height) ADJUSTMENT.
Damaged product should not be used. If a
damaged contact is evident, it should be
replaced. Contacts must not be re--terminated.
6. 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:
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 8,
REPLACEMENT.
7. MAINTENANCE AND INSPECTION
7.1. 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.
Ratchet Adjustment Wheel
Adjustment
Screw
Figure 4
CAUTION
!
CAUTION
!

408- 10309
SDE- SA Commercial Hand Tool Assembly for UTILUX Connectors
Rev D4 of 4 Tyco Electronics Corporation
7.2. 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 8, REPLACEMENT.
8. REPLACEMENT
Order replacements through your 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
9. REVISION SUMMARY
SRemoved Die Assembly 2119156--2.
Die Sets 2063765- 2 and 1976147-2 Can be Used in Tools Show Below
PRO- CRIMPER III Hand Tool 354940- 1
(Instruction Sheet 408-9930)
SDE Bench Terminator 1490076-2
(Customer Manual 409-10052)
Battery Tool (Shouldered Die) 1725837- 1, -2
(Customer Manual 409-10053)
Battery Tool (Pin Die) 1213890- 1, -2
(Customer Manual 409-10065)
626 Adapter 679304- 1
(Instruction Sheet 408-4070)
SDE- SA Hand Tool 9- 1478240-0
(Instruction Sheet 408-8851)