TE Connectivity SDE-SA User manual

Instruction Sheet
1 of 6
© 2017 TE Connectivity Ltd. family of companies.
All Rights Reserved.
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
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
2.5
1.88 ±0.05
1.5
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: