Instruction Sheet SDE-SA Commercial Hand Tool Assembly PN 2119156-1 with 408-10340 Die Assembly PN 2119156-2 15 May 17 Rev C 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. Die Set PN 2119156-2 TE Crimp Tooling Cable Wire Insulation UTILUX* Cable Type Conductor Diameter Strip Length SDE-SA Tool Die Assembly Connector Qty. mm inch Size mm inch mm inch 1 1-1659268-0 Advance Railway Cable 2 2119156-1 2119156-2 1 .75mm 18 3.0 .118 5.0 .197 (H2698) SDI.75 24/0 .20 Figure 1 INTRODUCTION SDE-SA Commercial Hand Tool Assembly for the UTILUX connector consists of the tool and die set shown in Figure 1. The tool utilizes the SDE-SA Frame Assembly 9-1478240-0 (Instruction Sheet 408-8851) and is used to crimp the terminal PN listed in Figure 1. NOTE Read these instructions thoroughly before using the hand tool. NOTE 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 reissue of this instruction sheet are provided in Section 9, REVISION SUMMARY. 1 Advance Wire and Cable Pty Ltd 2017 TE Connectivity Ltd. family of companies. PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. 1 of 5 All Rights Reserved. For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. 408-10340 DESCRIPTION The die set consists of an indenter (upper die) and an anvil (lower die). The tool frame holds a die assembly with one crimping chamber. See Figure 1. Die retaining screws are used to secure the dies in the tool frame. The tool frame features two jaws, a handle, a ratchet, a ratchet adjustment wheel with a range of settings, and an emergency ratchet release. 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. CAUTION The dies bottom before the ratchet releases. This feature ensures maximum tensile performance of the crimp. DO NOT re- adjust the ratchet. 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, the locator assembly, the four die retaining screws, and slide the anvil and crimper out of the tool jaws. NOTE The ratchet has detents with audible clicks as the handles are closed. The ratchet releases on the sixth click. CRIMPING PROCEDURE NOTE 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, RATCHET (CRIMP HEIGHT) ADJUSTMENT to verify crimp height before using the tool to crimp desired contacts and wire sizes. Referencing the table in Figure 1, select wire of the specified size and insulation diameter. Strip the wire to the length indicated. DO NOT 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 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 the open U of the wire barrel faces the top of the tool. Place the contact up into the nest so the front of the wire barrel is against the spring loaded locator. CAUTION Make sure both sides of the Wire Barrel are started evenly in the crimping section. DO NOT attempt to crimp an improperly positioned contact. 2 of 5 Rev C