TE Connectivity 1213875 Series User manual

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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

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Instruction Sheet

408-10231

Battery Operated Hydraulic

Crimping Tools

1213875-[ ] and 1976505-[ ] 25 MAR 14 Rev D

IMPORTANT SAFETY INFORMATION

ORIGINAL INSTRUCTIONS

408-10231

2of 5

Rev D

Figure 1

1. INTRODUCTION

This instruction sheet provides operation and

maintenance instructions for the Battery Operated

Hydraulic Crimping Tools 1213875-[ ] and 1976505-[ ].

See Figure 1.

Battery operated tools 1213875-[ ] have a 25.4 mm

[1 in.] stroke. Battery operated tools 1976505-[ ] have

a 38.1 mm [1.50 in.] stroke. Battery operated tools

1213875-1 and 1976505-1 have a 120 Volt charger.

Battery operated tools 1213875-2 and 1976505-2

have a 220 Volt charger.

The crimping head is designed to use dies that crimp

the terminals in Figure 2 which also lists the wire sizes

onto which the terminals and splices are crimped, as

well as the instruction sheet for the crimping dies.

Figure 2

Dimensions on this document are in metric units

[with U. S. customary units in brackets], unless

otherwisespecified.Figuresandillustrationsarefor

reference only and are not drawn to scale.

2. DESCRIPTION (Figure 1)

Main components of Battery Operated Hydraulic

Crimping Tools 1213875-[ ] and 1976505-[ ] include a

“C”-Head, which houses the stationary die; a piston

(ram), which houses the moving die and the die detent

mechanism; and a power unit, which houses the

hydraulic pump components. A removable battery is

also part of the functioning tool.

3. INSTALLATION

3.1. Battery Installation (Figure 3)

Slide the battery into the handle of the power unit until

it emits an audible and tactile click. The battery should

lock into position.

3.2. Die Installation

To avoid personal injury, do NOT accidentally

depress the trigger when installing or removing

dies.

Operating the head WITHOUT the crimping dies

installed will damage the “C”-Head or ram.

To install the die in the ram:

1. Remove the battery to prevent accidental

actuation.

2. Select the proper die set for the product to be

crimped.

3. Place the moving die half in the ram and press on

its side until the die snaps into place.

To install the die in the “C”-Head:

1. Remove the battery to prevent accidental

actuation.

2. Select the proper die set for the product to be

crimped.

3. Place the stationary die half in the “C”-Head and

press on its side until the die snaps into place.

4. CRIMPING PROCEDURE

The following procedure provides only general

information concerning crimping. Refer to the

instructions packaged with the dies (see Figure 2) for

detailed information, including wire stripping

dimensions and instructions for positioning terminals

and splices in the dies.

TERMINALS

(DOCUMENT)

WIRE SIZE (AWG) FOR:

BATTERYTOOL

1213875-[ ] BATTERYTOOL

1976505-[ ]

AMPOWER*

Terminals and Splices

(408-8703) 6 Through 2/0 6 Through 4/0

SOLISTRAND*

Terminals and Splices

(408-8691) 8 Through 4/0 8 Through 4/0

TERMINYL*

Terminals and Splices

(408-8704) 8 Through 4 8 Through 1/0

AMPLI-BOND*

Terminals and Splices

(408-8705) --- 8 Through 2

“C”-Head Ram

Power Unit Battery Crimp tool

1976505-1 Shown

Battery

NOTE

DANGER

STOP

CAUTION

408-10231

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Rev D

Figure 3

408-10231

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Rev D

1. Insert terminal or splice in the stationary die

according to the instructions packaged with the

dies.

2. Activate the power unit by depressing the trigger

to advance the dies and hold the terminal or splice

in place.

3. Insert stripped wire into the terminal or splice.

4. Activate the power unit to complete the crimp.

To ensure that the tool has reached full hydraulic

pressure, the cycle LED at the rear of the tool will

flash green for 5 seconds. See Figure 3.

If the red cycle LED is flashing red for 5 seconds,

the tool has not yet reached full pressure and the

crimping cycle should be considered incomplete.

See Figure 3.

5. INSPECTION/MAINTENANCE

Make sure hydraulic pressure is released and the

battery is detached before following inspection and

maintenance procedures, unless otherwise

specified in the procedure.

Each crimping tool is assembled and inspected before

shipment. It is recommended that the crimping tool be

inspected immediately upon its arrival, and at regularly

scheduled intervals, to ensure that the crimping head

has not been damaged during handling. Frequency of

inspection depends upon the following:

•Type and size of products crimped;

•Degree of operator skill; and

•Environmental conditions

If the wrench LED at the end of the tool is fully orange,

the tool has 1000 crimp cycles remaining before it

must be serviced. If the wrench LED is flashing

orange, there are 500 crimp cycles remaining. If the

wrench LED is flashing red, the tool is locked and

must be returned for service. See Figure 3.

Additionally, inspect and service the head (as

described in Figure 4) every month or 1,000 cycles,

whichever comes first. Refer to Figure 1.

5.1. Cleaning

Remove accumulations of dirt and grease on the

crimping tool, especially in areas where dies are

installed and terminals are crimped. Clean the entire

tool frequently with a clean, lint-free cloth.

5.2. Visual Inspection

In addition to the inspections listed in Figure 4, inspect

the head for nicks, scratches, and cracks. Inspect for

cracks especially at the corners of the “C”-Head and

around the top of the cylinder.

Inspect the metal surfaces for nicks, cracks,

scratches, and excessive wear, especially where

sliding contact occurs.

6. RETURN/REPAIR

Order replacement parts through your TE

Representative, or call 1-800-526-5142, or send a

facsimile of your purchase order to 1-717-986-7605, or

write to:

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

Crimping heads may also be returned for evaluation

and repair. For tool repair service, contact a TE

Representative at 1-800-526-5136.

7. REVISION SUMMARY

•Changed 1976505-1 to 1976505-[ ]

•Added new Figure 3

•Deleted Figure 4 and renumbered

•Deleted and added text to NOTE in Paragraph 4.4

•Changed text in Section 5

NOTE

DANGER

STOP

408-10231

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Rev D

Figure 4

ITEM TO BE INSPECTED INSPECTION/PROBLEM POSSIBLE SOLUTION

“C”-Head

Inspect for cracks, gouges, nicks, or galling

on the “C”-Head or where the “C”-Head

contacts dies.

Return tool for repair (see Section 6,

RETURN/REPAIR).

Check to see if the upper die retaining pin

does not hold the stationary die in place. Return tool for repair (see Section 6,

RETURN/REPAIR).

Cylinder

Inspect for evidence of cracks, gouges,

nicks, or galling. If there are cracks, return the tool for repair

(see Section 6, RETURN/REPAIR).

For traces of gouges, nicks, or galling:

Remove any sharp edges using a fine

emery cloth.

Ram

Inspect the ram in the Power “ON” (ram

advanced) position for evidence of galling,

cracks,or oil leaksbetweenthe ramand the

cylinder.

If there are cracks or leaks, return the tool

for repair (see Section 6, RETURN/

REPAIR).

Check to see if the moving die retaining ball

does not hold the moving die in place. Return tool for repair (see Section 6,

RETURN/REPAIR).

Inspect the ram in the Power “OFF” (ram

retracted) position to ensure that the ram

returns freely to its original position.

Return tool for repair (see Section 6,

RETURN/REPAIRS).

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