TE Connectivity SDE-SA User manual

Instruction Sheet

1 of 6

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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.te.com.

408-35024

12 APR 17 Rev A

Die Assembly

Contacts

Wire Size (mm2)

Insulation Diameter

Strip Length

2063531-2

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

Figure 1

INTRODUCTION

SDE-SA Hand Crimping Tool Assembly 2063531-1 consists of SDE-SA Frame Assembly 9-1478240-0 and die

set assembly 2063531-2 (see Figure 1). The tool is used to crimp MCP 2.8K Contact system. Refer to

Application Specification 114-18387 for contact application.

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 10, REVISION SUMMARY.

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 upper die consists of a wire crimper and

an insulation crimper, these components are held together by two spring pins and should not be separated.

The lower die consists of a wire anvil and an insulation anvil, these components are held together by two spring

pins and should not be separated. The tool frame holds a die assembly with four crimping chambers (see

Figure 1). Die retaining screws are used to secure the dies in the tool frame.

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.

SDE-SA Hand Tool Assembly;

PN 2063531-1, and Die Assembly

PN 2063531-2

Die Set 2063531-2

408-35024

Rev A

2 of 6

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.

When closed, the jaws form two crimping chambers each marked on the BACK side of the tool with the wire

size or range of wire sizes to be used in that nest (see Figure 1).

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 combined wire anvil and insulation anvil so that their chamfered sides and their marked

surfaces face outward, when mounted in the moving jaw of the tool frame.

3. 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.

4. 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.

5. 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.

6. Place a piece of paper between the dies and carefully close the tool handles, making sure that the

anvils and crimpers align properly. The paper helps to align the dies.

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, finish the ratchet cycle and

remove the paper.

7. Place the locator assembly over the end of the long screw, and position the locator assembly against

the side of the tool jaw.

8. 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.

9. To disassemble, close the tool handles until the ratchet releases, remove the nut, the locator

assembly, the two die retaining screws, and slide the anvils and crimpers out of the tool jaws.

CONTACT SUPPORT ADJUSTMENT [SEE FIGURE 2]

NOTE

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.

NOTE

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.

408-35024

Rev A

3 of 6

Figure 2

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.

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 6, CRIMP HEIGHT INSPECTION, and Section 7, CRIMP

HEIGHT (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.

CAUTION

Make sure that both sides of the Insulation Barrel are started evenly in the crimping section. DO NOT attempt to crimp an

improperly positioned contact.

408-35024

Rev A

4 of 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. TE Connectivity 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, CRIMP HEIGHT (RATCHET) ADJUSTMENT.

Maximum Wire Size

(mm2)

Crimp Section

(Wire Size Markings)

Crimp Height and Tolerance

2.5

1.88 ±0.05

1.5

1.58 ±0.05

1.0

0.50 - 1.0

1.23 ±0.05

0.35

0.20 - 0.35

0.98 ±0.05

Figure 3

CAUTION

Damaged product should not be used. If a damaged contact is evident, it should be replaced. Contacts must not be re-

terminated.

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 (see 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.

Position Point on Center of

Wire Barrel Opposite Seam

Modified Anvil

Crimp Height

(See Table)

408-35024

Rev A

5 of 6

Figure 4

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. Periodic 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.

REPLACEMENT

Order replacement parts through your TE 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)

TE CONNECTIVITY CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

REVISION SUMMARY

Initial release

408-35024

Rev A

6 of 6

Figure 5

Battery Tool (Pin Die) 2217481-1 and -2

Customer Manual 409-32032

Die Set 2063531-2 Can be Used in the Tools Shown Below:

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