Instruction Sheet
408-8733
SDE Crimping Die
Assemblies 91965-[ ]
08 OCT 10 Rev A
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.
Insulation
Adjuster
Shoulder
Screw
the wire. Each die is held in the SDE 1600 power tool
by shoulder screws.
3. DIE INSTALLATION (Figure 3)
3.1. Die Installation
Insulation
Indenter
1. Turn off the SDE 1600 Power Unit and
disconnect it from the power supply.
2. Depress the lever on the power unit to open
the die holders.
3. Install indenter dies in the stationary jaw of the
tool frame. Align the dies with the retaining screw
hole, then secure dies with the die-retaining
screws. Do NOT fully tighten dies.
PIDG*
Indenter
PIDG
Anvil
4. Install anvil dies in the movable jaw of the tool
frame. Align the dies with the retaining screw
hole, then secure dies with the die-retaining
screws. Do NOT fully tighten.
Insulation
Anvil
5. Release the lever on the power unit. This
allows spring pressure to close the jaws. The dies
will align themselves.
6. Install the locator assembly (packaged
separately) to the die assembly.
Figure 1
1. INTRODUCTION
SDE Premium Crimping Die Assemblies 91965-[ ]
(Figure 1) are designed to crimp the connectors in
Figure 2 onto wire when used in an SDE 1600 Power
Unit 1583034-[ ]. Refer to Figure 2 for a list of
connectors and the appropriate wire sizes.
Refer to instructions packaged with SDE 1600 Power
Unit for information concerning the power unit
1583034-[ ].
NOTE
i
Dimensions in this document are in metric units
[with U.S. customary units in brackets].
7. Securely tighten the die retaining screws while
the dies are bottomed.
NOTE
i
Dies are now installed. Die alignment and die
holding screw tightness should be checked at least
twice daily.
3.2. Die Removal
1. Depress the lever on the power unit to open
the die holders.
2. Turn off the SDE 1600 Power Unit and
disconnect it from the power supply.
3. Loosen the die holding screws and remove the
dies.
4. CRIMPING PROCEDURE
2. DESCRIPTION
Each crimping die assembly consists of two indenter
dies and two anvil dies, which when closed form two
crimping chambers. The larger crimping chambers
crimp the insulation of the connector onto the
insulation of the wire. The smaller crimping chamber
crimps the center contact onto the center conductor of
Select the appropriate wire size and connector. The
wire size and insulation diameter must be within the
specified range for the connector.
For detailed information on wire strip lengths and
proper assembly of the connector, refer to the
instructions packaged with the connector.
©2010 Tyco Electronics Corporation, Berwyn, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
All Rights Reserved
PRODUCT INFORMATION 1-800-522-6752
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
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
408-8733
WIRE
TERMINAL OR SPLICE
SIZE
(AWG)
INSULATION
DIAMETER
RANGE
12-10
3.81-6.35 [.150-.250]
STRIP
LENGTH
±0.397 [±0.16]
CRIMP DOT
CODE
(After Crimping)
RIDG (Pre Insulated Diamond Grip Terminal
Insulation
Barrel
Wire
Barrel
1
8.33 [.328]
Flat
Side
Strip
Length
16-14 HD
3.81-6.35 [.150-.250]
1
12-10
3.81-6.35 [.150-.250]
1
PLASTI-GRIP* Terminal
Striped Color
Code for HD
Color-Coded
Insulation
8.33 [.328]
16-14 HD
2.67-6.35 [.105-.250]
1
12
2.41-55.08 [.095-.200]
1
PIDG Insulation Restriction Terminal
Equally-Spaced
Shaded Stripes
9.92 [.391]
10
3.02-5.08 [.119-.200]
12-10
4.32-5.59 [.170-.220]
1
PIDG Butt Splice
Window Indent
Insulation
Barrel
9.13 [.359]
1
Wire Barrel
Figure 2
1. Turn on the SDE 1600 Power Unit and allow
approximately five seconds for the hydraulic
pressure to build up.
5. Insert stripped wire into terminal until wire butts
against locator. Insert stripped wire into splice
until wire butts against wire stop in splice.
2. Open the crimping dies by depressing the
control lever on the power unit.
6. Cycle the SDE 1600 Power Unit and hold
momentarily to complete the crimp. The terminal
or splice should be as shown in Figure 5 or
Figure 6
3. Then position the terminal between the
crimping dies (Figure 4). The terminal is properly
positioned when the tongue of the terminal is
under the locator and the wire barrel is against
the locator,
4. Release the control lever, allowing the dies to
spring shut and hold the terminal in place.
7. Remove the crimped terminal or splice.
8. When crimping a butt splice, reposition the
uncrimped half in the stationary die. It the splice
cannot be turned around turn the tool around,
load stripped wire in splice and cycle the power
unit.
9. Remove the butt splice.
Rev A
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408-8733
SDE 1600
Power Unit
(ref)
Indenter
Dies
Die
Retaining
Screws
PIDG
Locator
Assembly
Anvil
Dies
5. .INSULATION CRIMP ADJUSTMENT
i
PIDG terminals and splices feature an “insulation
grip.”
Each tool has four insulation crimp positions. See
Figure 1.
1. Loosen insulation adjustment locking screw
(see top of tool) and turn indicator to Position 4.
2. Place terminal or splice in tool dies.
3. .Insert UNSTRIPPED wire into ONLY the
insulation barrel of terminal or splice.
4. Perform a crimp. Remove crimped terminal or
splice and check insulation grip as follows: Bend
the wire back and forth once. Terminal or splice
should retain grip on wire insulation.
Wire
Barrel
Locator
6. Perform a crimp and repeat adjustment as
necessary until desired insulation grip is
obtained. Do not use a tighter setting than
required.
6. MAINTENANCE AND INSPECTION
Although the dies are inspected at the factory prior to
their shipment, it is recommended that a maintenance
and inspection program be performed at your facility
periodically. This is necessary to assure that continued
use of the dies will result in the same dependability
and uniform terminations for which the dies were
designed.
We recommend an initial frequency of once a month,
however frequency may be adjusted to suit your
requirements through experience. Frequency should
be dependant on:
Figure 3
NOTE
5. If the wire pulls out, set the insulation
adjustment indicator to next tighter position Position 3.
• Care, amount of handling, and use of the dies;
• Type and size of the product being crimped;
• Degree of operator skill;
• Presence of abnormal amounts of dirt and dust;
and
• Your own established standards.
6.1. 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 dies are not in use, store them in a
clean, dry area.
4. Store the tool with the tool handles closed to
prevent objects from becoming lodged within the
jaws.
6.2. Visual Inspection
1. Remove all lubrication and accumulated film
from the dies by immersing the dies in a suitable
commercial degreaser.
2. Make certain that all die-retaining screws and
die components are properly secured.
Tongue
Wire Barrel
Against Locator
3. Inspect the crimping surfaces for flattened,
chipped, worn, or cracked areas. If damage is
evident, the dies must be replaced. Refer to
Section 7, REPLACEMENT.
Figure 4
Rev A
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408-8733
Figure 5
Rev A
4 of 7
408-8733
Figure 6
6.3. Gaging the Crimping Chamber
Each tool is inspected for proper die closures before
packaging. An inspection should be performed
periodically to check the tool die closures for
excessive wear.
NOTE
i
The following plug gaging information for insulation
crimping chambers is provided for customers
specifically requiring this information. If plug gaging
is not required, inspect the die closures using an
alternate procedure, i.e., performing the “Insulation
Crimp Adjustment” (see Section 5) and “Visual
Inspection” (see Paragraph 6.3).
This inspection requires the use of plug gages
conforming to the dimensions listed in Figure 7. Tyco
Electronics does not manufacture or market these
gages. for information concerning plug gages and
micrometers, refer to 408-7424.
Rev A
To gage the crimping area(s), refer to Figure 8 and
proceed as follows:
1. Clean oil or dirt from the crimping chamber and
plug gage.
2. Cycle the SDE power unit until wire barrel dies
are bottomed. Do not apply additional pressure.
3. With wire barrel dies bottomed, inspect the
wire barrel crimping chamber using the proper
plug gage. Lift the spring-loaded locator up and
hold gage in straight alignment with the crimping
chamber. Carefully try to insert, without forcing,
the GO element. See Figure 8. The GO element
must pass completely through the crimping area.
4. Try to insert the NO-GO element. The NO-GO
element may enter partially, but must not pass
completely through the crimping area.
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408-8733
Suggested Plug Gage Design for
Insulation Barrel Section of Crimping Chamber
Suggested Plug Gage Design for
Wire Barrel Section of Crimping Chamber
Die Closure
Configuration
Die Closure
Configuration
GAGE ELEMENT DIMENSIONS
WIRE BARREL GAGE
INSULATION BARREL GAGE
GO
NO-GO
GO
NO-GO
W (Width) (Max)
4.293-4.300
[.1690-.1693]
4.442-4.445
[.1749-.1750]
1.626-1.633
[.0640-.0643]
2.131-2.134
[.0839--.0840]
4.34
[.171}
Figure 7
5. Set insulation adjustment indicator in Position
1. Measure insulation crimping chambers with the
proper GO plug gages in the same manner as
Steps 2 and 3. See Figure 8.
GO gage must pass completely
through the die closure.
NO-GO gage may enter partially,
but must NOT pass completely
through the die closure.
Insulation
Crimp
Wire Crimp
Plug Gage for
Wire Crimp Chamber
Plug Gage for Insulation
Crimping Chamber
Locator Assembly
Removed for Clarity
Figure 8
Rev A
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408-8733
6. With the insulation adjustment indicator in
Position 1, measure the insulation crimping
chambers with the proper NO-GO plug gages.
See Figure 8.
ensure that the dies have not been damaged during
shipment.
Order replacements through your local Tyco
Electronics representative, or call 1-800-526-5142, or
send a facsimile of your purchase order to 1-717-9867605, or write to:
If the crimping areas conform to the gage inspection,
the tool is considered dimensionally correct. If the
crimping areas do not conform to the inspection, the
tool must be repaired. Refer to Section 7,
REPLACEMENT.
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
7. .REPLACEMENT (Figure 9)
These crimping die assemblies are inspected before
shipment. It is recommended that the dies be
inspected immediately upon arrival at your facility to
Hex Nuts
986965-3
Locator
1583381-
8. REVISION SUMMARY
Since the previous release of this document, the TE
logo has been applied.
Spring
Lock
Washer
18025-2
Shoulder
Screws
133877-1
Spring Lock
Washer 18025-2
Button Head
Cap Screw
18024-6
Shoulder
Screws
133877-1
Hex Nuts
986965-3
Figure 9
Rev A
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