TE Connectivity SDE-SA User manual

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Instruction Sheet
TOOLING ASSISTANCE CENTER 1-800-722-1111
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 LOC B
408-10043
SDE-SA Hand Tool
Assembly 91391-1 with
Die Assembly 91391-2 12 JAN 12 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.
Figure 1
1. INTRODUCTION
SDE-SA Hand Tool Assembly 91391-1 consists of
SDE-SA Frame Assembly 9-1478240-0 and die set
assembly 91391-2. See Figure 1. The tool is used to
crimp 30-20 AWG Micro MATE-N-LOK* Pin and
Socket Contacts.
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.
2. 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 tool frame holds a die assembly
with two crimping chambers. See Figure 1. Die
retaining pins and die retaining screws are used to
position and secure the dies in the tool frame.
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.
The dies bottom before the ratchet releases. This
feature ensures maximum tensile performance of
the crimp. DO NOT re-adjust the ratchet.
3. 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.
Wire Crimper
(Upper Die)
Nut
Locator
Handle
Emergency
Ratchet Release
Stationary
Jaw Moving
Jaw
Anvil(Lower)
Wire Die Anvil (Lower)
Insulation Die
Die Retention
Screws
Retaining
Pins (4)
Required
Ratchet
Adjustment
Wheel
Insulation
Crimper
(Upper Die)
Die Set 91391-2
DIE
ASSEMBLY CONTACT WIRE
PART NUMBER SIZE (AWG) INSULATION DIA WIRE STRIP LENGTH
91391-2 794611-[ ] 30-26 0.89-1.53
[.035-.060] 2.90-3.53 [.114-.139]
794610-[ ] 24-20
NOTE
i
CAUTION
!
ORIGINAL INSTRUCTIONS

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Rev C
2. Place the 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 two die retaining pins.
4. 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.
5. 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.
6. Insert the two die retaining pins.
7. 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.
8. Carefully close the tool handles, making sure that
the anvils and crimpers align properly. 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.
9. Place the locator assembly over the end of the
long screw, and position the locator assembly
against the side of the tool jaw.
10. 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.
11. To disassemble, close the tool handles until the
ratchet releases, remove the nut, the locator
assembly, the two die retaining screws, and the four
die retaining pins, and slide the anvils and crimpers
out of the tool jaws.
The ratchet has detents with audible “clicks” as the
handles are closed. The ratchet releases on the
sixth “click”.
4. CONTACT SUPPORT ADJUSTMENT(Figure 2)
The contact support is presetprior 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.
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.
Figure 2
NOTE
i
NOTE
i
NOTE
i
BackofTool
(Wire Side)
Wire
Locator
Adjustment
Screw for
Contact
Support
Contact
Support
Contact
(Typ) Strip Length
Wire Inserted
to Stop
Locatorin
WireStop
Slot

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Rev C
5. Tighten the nut and close the handles until the
ratchet releases.
6. Remove and inspect the contact.
7. 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.
5. CRIMPING PROCEDURE
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, 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.
Make sure that both sides of the insulation barrel
are started evenly into the crimping section. Do not
attempt to crimp an improperly positioned contact.
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.
2. Refer to Section 5, CRIMPING PROCEDURE,
and crimp the contact(s) accordingly.
3. 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,
RATCHET ADJUSTMENT.
Damaged product should not be used. If a
damaged contact is evident, it should be replaced.
Contacts must not be re-terminated.
Figure 3
7. 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.
Refer to 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.
Figure 4
NOTE
i
CAUTION
!
WIRE SIZE
(AWG) CRIMP HEIGHT Dimension “A” and Tolerance (±)
30-26 0.58 ±0.05 [.023 ±.002]
24-22 0.74 ±0.05 [.029 ±.002]
20 0.89 ±0.05 [.035 ±.002]
CAUTION
!
PositionPointon
Center of Wire
Barrel Opposite
Seam
Modified Anvil
“A”
Adjustment
Screw Ratchet
Adjustment
Wheel

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8. 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. 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.
9. REPLACEMENT
Order replacements through your 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)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
10. REVISION SUMMARY
•Updated document to corporate requirements.
•Added new information to table in Figure 1 and
rearranged table

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Rev C
PRO-CRIMPER III Hand Tool Frame 354940-1
(Instruction Sheet 408-9930) SDE-SA Hand Tool 9-1478240-0 (Instruction Sheet 408-8851)
SDE Bench Terminator 1490076-2
(Customer Manual 409-10052) 626 Adapter 679304-1 (Instruction Sheet 408-4070)
Electro-Hydraulic (BT 3500 Battery-Hydraulic)
Hand Tool Kits 2031400-[ ]
(Customer Manual 409-10095) “C”-Head Assembly 2031450-1
(Instruction Sheet 408-10311)
Closed Head Assembly 2031460-1
(Instruction Sheet 408-10312)
Tooling Used with Dies 91391-2