Tyco Electronics 409-10052 Reference guide

409–10052
Customer Manual
1of 13
LOC B
E 2004TycoElectronicsCorporation,Harrisburg,PA
AllInternationalRightsReserved
AMP and Tyco are trademarks. *Trademark
Other products, logos, and company names used are the property of their respective owners.
TOOLINGASSISTANCECENTER800–722–1111This controlled document is subject to change.
10 MAR 04 Rev O
SDE Electric Bench Terminator 1490076–2
1. INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. RECEIVING INSPECTION AND INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1. ReceivingInspection 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2. Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1. Installation and Removal of SDE Tool Head 1763663–2 6. . . . . . . . . . . . . . . . . . .
4.2. Installation of Crimping Dies 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3. Terminator Power Supply 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4. ProductionOperation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. CRIMP HEIGHT ADJUSTMENT 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. TROUBLESHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. MAINTENANCEAND INSPECTION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1. Cleaning 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2. VisualInspection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3. Lubrication 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4. Parts List 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. REPLACEMENTAND REPAIR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. CIRCUITDIAGRAM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. REVISIONSUMMARY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
READ THIS FIRST ! 2. . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS

409–10052
SDE Electric Bench Terminator1490076–2
Rev O2 of 13
DANGER
SAFETY PRECAUTIONS AVOID INJURY
Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards during
equipment operation.However, certain safety precautions must be taken by the operator and repair personnel to avoid personal injury,
as well as damage to the equipment. For best results, application equipment must be operated in a dry, dust–free environment. Do not
operate equipment in a gaseous or hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
S ALWAYS wear appropriate ear protection.
S ALWAYS wear approved eye protection when operating powered equipment.
S ALWAYS keep guard(s) in place during normal operation.
S ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
S ALWAYS turn off the main power switch and disconnect electrical cord from the power source when performing maintenance
onthe equipment.
S NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
S NEVERinsert handsinto installedapplication equipment.
S NEVER alter, modify, or misuse the application equipment.
In addition, keep the following items in mind:
S Handle the terminator with caution and keep out of the reach of children.
S Do NOT remove components such as screws.
S Damage resulting from improper usage void the manufacturer’s warranty.
S Terminator cycle is initiated by means of a safety foot pedal which must be held down during the entire cycle. NOTE: The
safety lock of the foot pedal disengages when the foot pedal is floored.
S The terminator is provided with a swith for reverse operation.
S A counter records the number of cycles. A cycle is recorded each time the terminator is switched on or off.
S Two solid wrist supports on the terminator cover help reduce operator fatigue.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1–800–722–1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance Center offers a means of providing technical assistance when required.
In addition, Field Service Engineers are available to provide assistance in the adjustment or repair of the
application equipment when problems arise which your maintenance personnel are unable to correct.
When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person familiar with the device be
present with a copy of the manual (and drawings) to receive instructions. When calling the Tooling Assistance Center the following
informationis required:
INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER
6. Product part number (and serial number if applicable)
7. Urgencyof request
8. Nature of problem
9. Descriptionof inoperativecomponent(s)
10. Additionalinformation/comments thatmay behelpful
1. Customername
2. Customeraddress
3. Person to contact (name, title, telephone number, and
extension)
4. Personcalling
5. Equipment number (and serial number if applicable)

409–10052
SDE Electric Bench Terminator1490076–2
Rev O 3 of 13
Figure 1
1. INTRODUCTION
These instructions contain operation and setup procedures for the SDE Electric Bench Terminator 1490076–2.
This terminator has been manufactured in accordance with DIN EN ISO 9001.
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
Denotes an imminent hazard which may result in moderate or severe injury.
Denotes a condition which may result in product or equipment damage.
Highlightsspecial orimportant information.
Dimensions in this manual are in metric units [with U.S. customary units in brackets].
Read and understand these instructions completely before attempting to operate the terminator.
2. DESCRIPTION
This terminator is equipped with a holder for tool heads, allowing a quick installation and removal of the various
tool heads. The terminator is activated by means of a foot pedal which must be operated during the entire work
cycle to meet all CE–safety requirements.
DANGER
CAUTION
NOTE
NOTE

409–10052
SDE Electric Bench Terminator1490076–2
Rev O4 of 13
A further safety component is a safety lock on the foot pedal. The ergonomic design of the foot pedal cover
supports the foot of the operator. The sturdy workmanship of the unit is designed for long lasting performance.
Specifications for SDE Electric Bench Terminator 1490076–2 are contained in Figure 2.
SPECIFICATIONS
Dimensions: 390mm X 260mm X 200mm [15.5 in. X 10 in. X 8 in.]
Weight:: 13kg [ 29 lbs]
Power Requirements: 220 Vac / 240 Vac, 50/60 Hz –– 110 Vac / 120 Vac, 60 Hz
Power Consumption: .7 KVA Max.
Figure 2
Identification of items on SDE Electric Bench Terminator 1490076–2 can be found in Figure 3.
Figure 3
Tool Head Holder
Locating Pins for
Fastening
of Tool Head
Double–ThrowSwitch for
ReverseOperation
Jogging Switch for
Vario–Operation
Signal
Lamp
Counter
ON–OFF
Switch
Rotary Switch for
Vario–Adjustment
Ram

409–10052
SDE Electric Bench Terminator1490076–2
Rev O 5 of 13
An identification of the front panel controls can be seen in Figure 4.
Figure 4
ON/OFFSwitch Counter
SignalLamp
180°JoggingSwitch Position“Standard Operation”
(Press One Time for a Full Cycle
180°Jogging Switch Position “Vario–Operation”
(Adjustment by Knob on Left Side of Terminator)
Press 2 Times for a Full Cycle
DoubleThrow Switch
(Retracts Ram to Lowest Position)
An identification of the rear mounted controls can be seen in Figure 5.
Figure 5
Voltage Selector Fuses
MainPower Receptacle
Socket for Foot Pedal

409–10052
SDE Electric Bench Terminator1490076–2
Rev O6 of 13
3. RECEIVING/INSPECTION AND INSTALLATION
3.1. Receiving/Inspection
The SDE Electric Bench Terminator 1490076–2 is thoroughly inspected during and after assembly. Prior to
packaging and shipping, a final series of tests and inspections is made to ensure proper functioning of the
terminator. The following inspection should be performed as a safeguard against potential problems generated
in transit. The components of the terminator are packaged so that they can be removed from the packaging and immediately
installed, as described in Paragraph 3.2.
1. In a well–lighted area, carefully uncrate the terminator and inspect each component as it is removed
from the crate.
2. Thoroughly inspect each component for evidence of damage that may have occurred in transit. If any
of the components are damaged, file a claim against the carrier and notify Tyco Electronics
immediately.
3. Inspect all electrical lines for evidence of damage.
It is important that this manual and other documents (such as drawings and parts lists), as well as any enclosed
product samples, remain with the terminator for the benefit of personnel responsible for installation, operation,
andmaintenance.
3.2. Installation
Place the SDE Electric Bench Terminator 1490076–2 on a well lit desktop. Plug the electrical cord into the
electrical outlet (refer to Figure 2 for power requirements, and Paragraph 4.4,A for instructions on plugging the
cord into the outlet).
If required, secure the terminator to the bench.
4. OPERATION
To avoid personal injury, do not cycle the SDE Electric Bench Terminator without the toolhead installed.
4.1. Installation and Removal of SDE Tool Head 1673663–2
A. Installation
Before mounting the SDE tool head, always make sure that the guide ram of the terminator is in the lowest
position. (Refer to Figure 6.)
To avoid personal injury, be sure the SDE Electric Bench Terminator is disconnected from the power source prior to
the installation or removal of the tool head.
1. Be sure that the terminator has been switched off.
2. Be sure that the SDE tool head is mounted with opening for the dies in the front, to facilitate die
installation and removal.
3. Mount the head from the back and lock with the safety pins. (Refer to Figures 7 and 8.)
4. Refer to Paragraph 4.2, to remove and install the crimping dies.
B. Removal
To avoid personal injury, be sure the SDE Electric Bench Terminator is disconnected from the power source prior to
the installation or removal of the tool head.
1. Be sure the terminator has been switched “off.”
2. Remove the locating pins from the tool holder.
3. Remove and/or replace the tool head.
4. When removing the tool head, make sure that the guide ram of the terminator is in the lowest
position.
5. If installing or removing crimping dies, refer to Paragraph 4.2.
4.2. Installation of Crimping Dies
To avoid personal injury, be sure the SDE Electric Bench Terminator is disconnected from the power source prior to
the installation or removal of the crimping dies.
NOTE
NOTE
DANGER
DANGER
DANGER
DANGER

409–10052
SDE Electric Bench Terminator1490076–2
Rev O 7 of 13
Figure 6
GuideRam
Figure 7
Tool Head
ControlLever
Figure 8

409–10052
SDE Electric Bench Terminator1490076–2
Rev O8 of 13
These instructions are specific to the use of Tyco Electronics SDE crimping dies. BE SURE to use only Tyco
Electronics crimping dies.
A. Installation of Shouldered Dies
1. Remove the two die retaining screws from the tool head.
Be sure to keep the die retaining screws. They WILL be required to install shouldered dies.
2. Depress the control lever to open the tool head and place the upper die in the upper jaw of the tool
head so that the largest indenter is facing inward.
3. Insert the die retaining screw through the upper jaw and through the die. Tighten the screw just
enough to hold the die in place. Do NOT tighten the screw completely at this time.
4. Place the lower die in the moving jaw of the tool head so that the largest anvil is facing inward.
5. Insert the die retaining screw through the lower jaw and through the die. Tighten the screw just
enough to hold the die in place. Do NOT tighten the screw completely at this time.
6. Release the control lever to close the tool head, making sure the anvils and indenters align properly.
Hold the tool head closed to keep the dies in place, and then tighten both retaining screws.
7. To disassemble, open the tool head, remove the two die retaining screws, and slide the dies out of the
tool head.
B. Installation of Pinned Dies
1. Remove the two die retaining screws from the tool head.
Be sure to keep the die retaining screws. Although they will not be required to install pinned dies, you may need
them for future use.
2. Depress the control lever to open the head and install the anvil die into the moving jaw of the tool
head. The die assembly should be oriented so that the chamfers are positioned toward the front of the
head assembly, and the die markings are facing outward.
3. Insert two die retaining pins and the short die retaining screw into the moving jaw and through the
anvil die. Tighten the screw just enough to hold the die in place. Do
NOT completely tighten the screw at
this time.
4. Install the crimper die into the upper crimping upper crimping jaw of the tool head. The die should be
oriented so that the chamfers are positioned toward the front of the head assembly and the die markings
are facing outward.
5. Insert two die retaining pins and the long die retaining screw into the upper jaw and through the the
crimper die. Tighten the screw just enough to hold the die in place.
6. Check the die alignment by releasing the control lever to close the tool head, making sure the anvil
and indeter align properly. When the dies are properly aligned, fully tighten the the die retaining screws.
7. Install the locator assembly onto the long retaining screw and secure it with the appropriate hex nut.
8. To remove the dies from the tool head, open the tool head, remove the die retaining pins and screws,
and slide the dies out of the tool head.
4.3. Terminator Power Supply
The terminator can be operated with 220/240 Vac or 110/120 Vac. The voltage selector is located at the rear
side of the terminator. The terminator is set
The terminator is set by the manufacturer at 220/240 Vac.
4.4. Operation
To avoid personal injury, keep fingers clear of the crimp dies when operating the tool. Never place anything in the
crimping dies but terminals and splices.
CAUTION
NOTE
NOTE
NOTE
DANGER

409–10052
SDE Electric Bench Terminator1490076–2
Rev O 9 of 13
A. Normal Production Operation
This procedure assumes that the tool head and dies have been installed.
1. Connect the provided power cord into the receptacle at the rear of the terminator, and then into the
power outlet.
2. Move the ON/OFF button to Position No.“|”.
The green signal lamp should light when the ON/OFF switch is in Position No. “|”. If the signal lamp does
not light, check the fuses at the rear of the terminator. These fuses can be checked after rotating and
removing the the back fuse holders.
3. Connect the foot pedal to the foot pedal socket at the rear of the terminator. Lock the pedal in place
by turning the connector clockwise.
The foot pedal is equipped with a safety lock, which prevents operation of the terminator when the foot
pedal has been completely floored due to excessive pressure applied to the foot pedal.. This safety lock
can be released by turning the knob on the foot pedal back to its original position. Now the terminator is
ready for operation again.
The dies are normally closed, for safety reasons. The dies are opened (retracted) with the control lever at the front of
the tool head in order to insert the connector to be crimped.
4. After the connector is properly positioned in the crimp dies, release the control lever to allow the dies
to spring shut, holding the connector in position.
5. Insert the stripped wire, then apply moderate pressure to the foot pedal to cycle the terminator.
The foot pedal must be held down constantly to ensure a complete working cycle.
6. Open the dies by depressing the control lever, and remove the completed crimp.
B. Vario–Operation (Figure 9)
The terminator can be operated also in “double step” mode. When the terminator has been switched to
Vario–operation, it can be operated with two separate and distinct steps: First step for holding the inserted
contact, second step for crimping and moving back into the final position.
The Vario–position can be adjusted to the respective contact material (1 = min; 6 = max.) by means of the
knob for Vario–adjustment (refer to Figure 3).
C. Reverse Rocker Switch
If it is necessary to retract the dies without completing the crimping cycle, depress and hold the reverse
rocker switch to return the guide ram of the tool head to the lowest position.
Figure 9
Maximum Position of the Knob
(Position6)
Minimum Position of the Knob
(Position1)
NOTE
NOTE

409–10052
SDE Electric Bench Terminator1490076–2
Rev O10 of 13
5. CRIMP HEIGHT ADJUSTMENT
Crimp height adjustment is only required only if the crimp height listed in the Tyco Electronics die specification
is not achieved.
Adjust the crimp height with a flat–bladed screwdriver.
There are four different crimp heights. Refer to Figure 10.
Although Tyco Electronics normally recommends Position No. 2 (adjustment of the manufacturer), Positions No. 3 and
No. 4 increase the travel of the tool head, which decreases the crimp height. Position No. 1 decreases the the travel of
the head, which increases the crimp height.
Figure 10
CrimpHeight Adjustment
(One Step Equals 0.1mm [.004 In.])
NOTE

409–10052
SDE Electric Bench Terminator1490076–2
Rev O11 of 13
6. TROUBLESHOOTING
Refer to Figure 11 for troubleshooting information.
PROBLEM ACTION
’
Check correct position of connecting cable
Signal lamp doesn
’
t light ON/OFF switch in Position “|”?
Inspect fuses
Power supply o.k.? Signal lamp lights up?
Foot pedal correctly connected?
Terminator cannot be operated Foot pedal locked in?
Release the safety lock by turning knob..
Terminator performs only a half cycle 180°Jogging switch in “Vario” position. Switch it to “Standard.”
180°Jogging–switch in “Vario” position!
Terminator not in final position Switch to “Standard”and try again
Tool head cannot be installed in
Terminator not in final position Move the device to start position by means
of the double throw switch
Tool head cannot be installed in
holder Tool head not in final position! Move crimp anvil to lowest position (see the
instruction sheet of the appropriate tool
head)
Tool head ram doesn’t engage correctly in
terminator ram Refer to Paragraph 4.1, Installation/Removal of the Tool Head
’
Move the terminator stepwise back by means of the double throw switch
Tool head doesn
’
t open Clean and lubricate tool head in the crimp area and inspect for damages
CAUTION: Never use a damaged tool!
Tool head is under preload
Tool head cannot be removed Move back stepwise by means of the double–throw switch until tool head can be removed.
Figure 11
7. MAINTENANCE AND INSPECTION
To avoid personal injury, ALWAYS disconnect the SDE Electric Bench Terminator beforeperforming any maintenance
orinspection.
Tyco Electronics recommends that a maintenance and inspection program be performed periodically to ensure
dependable and uniform terminations. The SDE Electric Bench Terminator should be inspected monthly.
Frequency of inspection should be adjusted to suit your requirements through experience. Frequency of
inspection depends on:
S The care, amount of use, and handling of the terminator.
S The type and size of the product crimped.
S The degree of operator skill.
S The presence of abnormal amounts of dust or dirt.
S Your own established standards.
It is recommended that all moving parts (particularly the movable driving parts) of the tool be lubricated from
time to time. Lubrication not only keeps the tooling operating efficiently, it protects the tooling from humidity.
For die closure inspections and plug gage dimensions, as well as inspections of the crimp areas, and crimping die
maintenance, refer to the appropriate die assembly instruction sheet.
7.1. Cleaning
Remove dust, moisture, and other contaminants with a clean soft brush, or a soft, lint–free cloth. Do NOT use
objects or cleaning materials that could damage tooling. Re–lubricate the sliding surfaces of the head assembly
as described in Paragraph 6.3 before placing the head back into service.
DANGER
NOTE

409–10052
SDE Electric Bench Terminator1490076–2
Rev O12 of 13
7.2. Visual Inspection
1. Inspect the tool head assembly for missing heads or screws. Check all movable drive parts and tool
head surfaces for wear.
2. Inspect the crimp areas in the die assembly for flattened, chipped, or broken areas. Although the dies
may gage within permissible limits, worn or damaged die closure surfaces may affect the quality of the
crimp.
7.3. Lubrication
Lubricate all movable driving parts with a high quality grease. Tyco Electronics recommends the use of
Molycote paste (which is a commercially available lubricant).Lubricate according to the following schedule:
S Lubricate the head assembly used in daily production on a daily basis
S Lubricate the head assembly (used occasionally) in daily production on a weekly basis
S Lubricate the head assembly used weekly on a monthly basis
Wipe the excess grease from the head assembly, particularly in the die closure areas. The grease transferred
from the die closure die closure area onto certain terminations may affect the electrical characteristics of a
termination.
7.4. Parts List
Figure 12 contains a basic parts list for the SDE Electric Bench Terminator.
8. REPLACEMENT AND REPAIR
Basic replacement parts are listed in Paragraph 7.4. Parts SHOULD be replaced by Tyco Electronics to
ensure quality and reliability of the head assembly and terminator. Order replacement parts through your Tyco
Electronics Representative, or call 1–800–526–5142, or send a facsimile of your purchase order to
1–717–986–7605, or write to:
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105 – 3608
ITEM DESCRIPTION PART NUMBER
1SDE Electric Bench Terminator 1673677–1
2Head, SDE Electric Bench Terminator 1673663–2
3Foot Pedal 1673664–1
Figure 12

409–10052
SDE Electric Bench Terminator1490076–2
Rev O 13 of 13
9. CIRCUIT DIAGRAM
Figure 13 contains the terminator circuit diagram.
Figure 13
10. REVISION SUMMARY
New release per EC 0990–0301–04