Revisions Sym Description Date Approved C Revised per E.O. P21338 12-04-12 D.G.M C1 Changed DEUTSCH to TE throughout document 03-25-15 D.G.M CONTENTS Section: Topic: Page: 1.0 Wire Preparation............................................... 2 2.0 Contact Loading............................................... 2 3.0 Crimp Set-Up.................................................. 2 3.1 Conductor Crimp Height/Width Adjustment..................... 2 3.2 Insulation Crimp Adjustment.................................. 3 4.0 Contact Removal............................................... 3 5.0 Troubleshooting................................................ 3 5.1 Wire Stop Adjustment........................................... 3 5.2 Contact Feed Adjustment........................................ 4 6.0 Maintenance................................................... 4 7.0 DCT20-02-00 Schematic......................................... 5 8.0 DCT20-02-00 Spare Parts List.................................... 6 Revision Letter: C1 Engineering Order Number: Page 1 of 6
1.0 WIRE PREPARATION Prior to crimping contacts, strip.175.025 inch (4.83 mm 0.64 mm) of insulation from wire. Correctly stripped wire has neither insulation tearing nor stretching, nor strand damage. 2.0 CONTACT LOADING Circled numbers refer to location on DCT20-02-00 schematic (Section 7.0). Press shutheight should be set at 5.346 inches (135.79 mm). WARNING: Applicator die DCT20-02-00 is used in many types of presses (manual and auto-matic), therefore guarding is not provided. It is the PURCHASER S RESPONSIBILITY to GUARD all pinch points and moving parts. Before attempting any adjustments or repairs, ALWAYS DISCONNECT THE ELECTRICAL POWER. In order to properly install the contact: 1) Turn brake clockwise to release position (as shown on schematic). 2) Feed contacts into applicator die from left side. Ensure that insulation crimp ears enter the insulation crimp ear alignment groove. 3) Push contacts past feed finger. Continue pushing contacts until first contact is centered with cutter (ref 5.2). 4) Apply tension toward left and turn brake 180 counterclockwise to set position. 5) Slowly cycle press to ensure correct contact installation, alignment and feed (If the press will not cycle, crimp heights may be set too low; ref 3.0) 3.0 CRIMP SET-UP Crimp dial settings ( & ) are for reference only. Only crimps that meet the height and width specifications on TE print 0425-207-0000 can be relied upon to perform correctly. Tensile strength alone is not an appropriate indication of crimp quality. Crimp height and width should be checked on a regular basis to ensure consistent quality. Adjustment of mechanical press may be required in addition to applicator die adjustment to achieve proper crimp heights. 3.1 CONDUCTOR CRIMP HEIGHT/WIDTH ADJUSTMENT Conductor crimp height and width must be as specified in TE drawing 0425-207-0000. Change conductor crimp height by adjusting the lettered dial on top of the applicator die. Revision Letter: C1 Engineering Order Number: Page 2 of 6
Ascending dial settings give minimum crimp heights. Descending dial settings give maximum crimp heights. Dial steps are.005 inch (0.127 mm) each. Correct conductor crimps will capture all wire strands within the contact ears. Material extrusion (burrs) under the conductor crimp are normal but should not exceed.010 inch (0.25 mm). Note: Adjusting conductor crimp height will also affect insulation crimp height. 3.2 INSULATION CRIMP ADJUSTMENT Insulation crimp diameter should be the insulation diameter or less. Crimp shall neither hinder removal tool nor damage connector grommet. Reference TE drawing 0425-207-0000. Change insulation crimp height by rotating dial counter-clockwise for maximum height and clockwise for minimum height. Dial steps are.010 inch (0.25 mm) each. Note: Adjusting insulation crimp height will affect conductor crimp height inversely (decreasing insulation crimp height will slightly increase conductor crimp height). 4.0 CONTACT REMOVAL To remove contacts from applicator die: 1) Turn brake clockwise to release position. 2) Lift feed finger while pulling contact strip from die. 5.0 TROUBLESHOOTING 5.1 WIRE STOP ADJUSTMENT Wire Stop is factory set and should only be adjusted if needed to meet this visual inspection: If crimped contacts do not pass this visual inspection, adjust wire stop as follows: 1) Disconnect electrical power to press. 2) Hand cycle press to move ram to the down position. 3) Loosen lockscrew on wire stop. 4) Slide wire stop to required position. 5) Tighten lockscrew. 6) Hand cycle applicator die to assure correct clearance operation. WARNING: 5.2 CONTACT FEED ADJUSTMENT Wire Stop should only be adjusted with ram cycled in the down position in order to avoid potential punch damage. Wire Stop must not touch any moving tooling. Revision Letter: C1 Engineering Order Number: Page 3 of 6
Contact feed is set at the factory and should not require adjustment. To adjust contact feed to advance ( right) or to retard ( left): 1) Disconnect electrical power to press. 2) Remove cutter holder and cutter to view alignment with anvils. 3) Single-cycle press to locate contact above anvils (with brake tension applied). 4) Loosen feed adjustment lockscrew. 5) Turn feed finger adjustment counter-clockwise to advance feed (right ). 6) Turn feed finger adjustment clockwise to retard feed (left ). Brake must be released by turning clockwise while lightly pulling contact strip left. Reset brake by turning counter-clockwise after retarding contact feed. 7) Re-tighten lockscrew. 8) Replace cutter and cutter holder. 6.0 MAINTENANCE To ensure correct functioning and maximum service life of the applicator die, maintenance must be performed on a regular basis. This maintenance may include but is not limited to: 1) Lubrication of moving parts. 2) Removal of swarf (cut off material) from applicator, especially in areas including or near feed mechanisms, anvils, punches, etc. 3) Replacement of worn parts. 4) Visual inspection for loose hardware, broken or missing parts. 5) Proper operation of press safety equipment. WARNING: Before attempting any adjustments or repairs, ALWAYS DISCONNECT THE ELECTRICAL POWER. After performing maintenance, ALWAYS REPLACE any SAFETY GUARDS which may have been removed. Revision Letter: C1 Engineering Order Number: Page 4 of 6
Conductor Crimp Adjustment Dial Insulation Crimp Adjustment Dial Wire Stop and Lock Screw Feed Adjustment Lock Screw Feed Adjustment Rod Contact Feed Assembly Brake (shown unlocked) Cutter Holder Cutter 7.0 DCT20-02-00 SCHEMATIC Revision Letter: C1 Engineering Order Number: Page 5 of 6
A 1017-483-0200 Cutter Punch B 1017-***-0200 Insulation Punch C 1017-***-0200 Conductor Punch C 1017-761-0200 Conductor Punch D 1017-463-0200 Gathering Insert E 1017-470-0200 Gathering Insert Spring F 1017-487-0200 Conductor Depressor F 1017-763-0200 Conductor Depressor G 1017-488-0200 Conductor Depressor Spring H 1017-465-0200 Conductor Depressor Holder I 1017-510-0200 Pressure Pad J 1017-471-0200 Pressure Pad Spring K 1017-467-0200 Pressure Pad Holder L M6 x 35 SHCS Punch Screw N 1017-479-0200 Rear Anvil Holder P 1017-***-0200 Conductor Anvil P 1017-762-0200 Conductor Anvil R 1017-***-0200 Insulation Anvil S M4 x 13 SHCS Anvil Screw T 1017-482-0200 Cutter U 1017-473-0200 Cutter Springs V 1017-460-0200 Cutter Holder NS 1017-468-0200 Feed Finger (Not Shown) NS 1017-469-0200 Wire Stop (Not Shown) Notes: See TE drawing 0425-207-0000 for specific punch and anvil recommendations. Consult TE Applicator Tooling for parts not listed. Use Alternate Parts for 106*-20-06** 2.5mm² Contact. 8.0 DCT20-02-00 SPARE PARTS LIST Revision Letter: C1 Engineering Order Number: Page 6 of 6