Tyco Electronics SDE-SA 2063526 Series Bedienungsanleitung

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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

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

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

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

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:

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