TE Connectivity 1213890-1 Reference guide

409--10065

Customer Manual

SDE Closed Head

1of 9

LOC B

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company

*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.

TOOLING ASSISTANCE CENTER

1--800 -- 722 -- 1111

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com

13 JUL 11 Rev F

Battery Powered Crimp

Tool Kit 1213890- [ ]

READ THIS FIRST ! 2.........................

SAFETY PRECAUTIONS

1. INTRODUCTION 5...................................................

2. RECEIVING/INSPECTION 5............................................

3. INSTALLATION/REMOVAL OF SDE CRIMP DIES 5...........................

3.1. Installation of SDE Crimp Dies 5......................................

3.2. Removal of Shouldered and Pinned Dies 8..............................

4. OPERATION 8......................................................

4.1. Battery Installation and Removal 8....................................

4.2. Crimping 8.....................................................

5. PREVENTIVE MAINTENANCE 9........................................

5.1. Daily Maintenance 9..............................................

5.2. Yearly Maintenance 9..............................................

6. SPARE PARTS 9....................................................

7. TROUBLESHOOTING 9...............................................

8. RETURN 9.........................................................

9. REVISION SUMMARY 9...............................................

Safeguards are designed into this application equipment to protect operators and

maintenance personnel from most hazards during equipment operation. However,

certain safety precautions must be taken by the operator and repair personnel to

avoid personal injury, as well as damage to the equipment. For best results,

application equipment must be operated in a dry, dust--free environment. Do not

operate equipment in a gaseous or hazardous environment.

Carefully observe the following safety precautions before and during operation of

the equipment:

DALWAYS wear appropriate ear protection.

DALWAYS wear appropriate eye protection.

DALWAYS wear approved eye protection when operating powered equipment.

DALWAYS keep guard(s) in place during normal operation.

DNEVER wear loose clothing or jewelry that may catch in moving parts of the

application equipment.

DNEVER insert hands into installed application equipment.

DNEVER alter, modify, or misuse the application equipment.

ORIGINAL INSTRUCTIONS

409- 10065

Rev F2of 9

SAFETY PRECAUTIONS - - IMPORTANT SAFETY INFORMATION

DANGER

DANGER This unit should only be used by trained

competent personnel.

Read and understand the entire manual

before using the equipment.

Always wear approved eye protection

when using the equipment.

NOTE: Keep all decals clean and legible, and replace

when necessary.

CAUTION

409- 10065

Rev F 3of 9

TOOLING ASSISTANCE CENTER

CALL TOLL FREE 1 - 800 - 722 - 1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

The Tooling Assistance Center offers a means of providing technical assistance when required.

In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the

application equipment when problems arise which your maintenance personnel are unable to correct.

INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER

When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person

familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many

difficulties can be avoided in this manner.

When calling the Tooling Assistance Center, be ready with the following information:

01. Customer name

02. Customer address

03. Person to contact (name, title, telephone number, and extension)

04. Person calling

05. Equipment number (and serial number if applicable)

06. Product part number (and serial number if applicable)

07. Urgency of request

08. Nature of problem

09. Description of inoperative component(s)

10. Additional information/comments that may be helpful

BATTERY TOOL KIT REGION OF USE BATTERY CHARGER BATTERY CHARGER

VOLTAGE

RAM RETRACT

SWITCH

1213890--1 North America 1725840--1 110 V Yes

1213890--2 Europe 1725840--2 220 V Yes

1213890--3 North America 1725840--1 110 V No

1213890--4 Europe 1725840--2 220 V No

1213890--5 United Kingdom 1725840--3 220 V Yes

409- 10065

Rev F4of 9

SDE Crimp Die

Location

Release Switch

(1213890--1, --2,

and --5 Only)

Battery

Lock

Battery

Cartridge

1725839--1

Battery Powered

Crimp Tool

SDE Closed Head

Adapter Assembly

CRIMPING TOOL (with Battery Installed)

Length 349 mm [13 3/4 In.]

Width 60 mm [2 3/8 In.]

Depth 80 mm [3 1/8 In.]

Mass/Weight (w/Battery) 1.5kg[3.4lb.]

Sound Level 75 dBA at 1 Meter

Vibration <2.5m/s2

Hydraulic Oil Shell TellusT15

CRIMPING CAPACITIES

Maximum Crimping Force 15.6 kN [1.75 Tons]

Average Crimping Time 2 Seconds

Average Crimps Per Charge Approximately 150

BATTERY

Charging Voltage 9.6 V

Charging Time 40 Min

Figure 1

409- 10065

Rev F 5of 9

1. INTRODUCTION

SDE Closed Head Battery Powered Crimp Tool Kit 1213890--[ ] consists of the SDE Battery Powered Crimp

Tool (with the SDE Closed Head Assembly installed), as well as two rechargeable battery cartridges

(1725839--1) to power the tool. See Figure 1. Each kit has a battery charger. The battery charger part number,

its voltage, and the kit’s region of use are listed in the table below. A battery tool may have a release switch to

retract the ram as listed in the table on Page 3. The SDE Closed Head Battery Powered Crimp Tool is

designed to accept interchangeable die assemblies used in PRO--CRIMPER* III hand crimping tools for

crimping various types of connectors.

2. RECEIVING/INSPECTION

SDE Closed Head Battery Powered Crimp Tool Kit 1213890--[ ] is thoroughly inspected during and after

assembly. Prior to packaging and shipping, a final series of tests and inspections is made to ensure proper

function of the tool. The following inspection should be performed as a safeguard against potential problems

generated in transit.

1. In a well--lighted area, carefully uncrate the tool and inspect each component as it is removed from

the crate.

2. Thoroughly inspect each component for evidence of damage that may have occurred in transit. If any

of the components are damaged, file a claim against the carrier and notify TE Connectivity immediately.

3. Keep this manual and all drawings and product samples with the tool for the benefit of operation and

maintenance personnel.

The crimp tool should be inspected at regularly scheduled intervals, depending on care, degree of operator

skill, the type and size of product being crimped, and environmental conditions. At a minimum, the tool should

be inspected after every 40 hours of use.

3. INSTALLATION/REMOVAL OF SDE CRIMP DIES

Do not operate the tool without the SDE Crimp Head Installed. Damage to the ram or seals can result.

Do not operate the tool without the SDE dies. Damage to the crimp head can result.

SDE Closed Head Battery Powered Crimp Tool 1213890--[ ] comes with the crimp head already installed on the

battery--powered hand tool. The only installation required is the installation of the SDE dies.

To avoid personal injury, be sure to exercise extreme caution when handling the crimp tool. Remove the battery before

installing or removing crimp dies.

3.1. Installation of SDE Crimp Dies

These instructions are specific to the use of TE SDE Crimp Dies. Be sure to use ONLY TE Crimp Dies.

The SDE Battery Operated Crimp Tool cannot be used to crimp parallel splices.

CAUTION

DANGER

CAUTION

NOTE

409- 10065

Rev F6of 9

A. Installation of Shouldered Dies (Figure 2 )

1. Remove the battery from the tool.

2. Remove the two die retaining screws from the crimp head.

3. Remove the ram plate from the moving jaw.

4. Place the upper die in the upper portion of the tool head so that the largest indenter is on the right.

5. Insert the die retaining screw through the upper jaw and through the die. Tighten the screw just

enough to hold the die in place. Do NOT tighten the screw completely at this time. See Figure 2.

6. Place the lower die in the moving jaw of the crimp head so that the largest anvil is on the right.

7. Place the ram plate on the moving jaw. The chamfers on the corners of the ram plate should be

located adjacent to the die set.

8. Insert the die retaining screw through the ram plate; die set, and the moving jaw. Tighten the screw

just enough to hold the die in place. Do NOT tighten the screw completely at this time.

9. Replace the battery and pulse the trigger to slowly close the crimp head, making sure the anvils and

indenters are properly aligned.

10. When the anvils and indenters are aligned, tighten the retaining screws.

Figure 2

Upper Die

Retaining

Screw

Upper SDE Die

Lower Die Retaining Screw

Lower SDE Die

Moving Jaw

Upper Jaw

Ram Plate

Machine Screw

Chamfer on

Ram Plate

409- 10065

Rev F 7of 9

B. Installation of Pinned Dies (Figure 3)

1. Remove the battery from the tool.

2. Remove the two die retaining screws from the crimp head.

Be sure to keep the die retaining screws. Although they will not be required to install pinned dies, you may need them

for future use.

3. Remove the ram plate from the moving jaw.

4. Install the anvil die into the moving jaw of the crimp head. The die assembly should be oriented so

that the chamfers are positioned to the left of the head assembly, and the die markings are facing

outward.

5. Place the ram plate on the moving jaw. The chamfers on the corner of the ram plate should be

located adjacent to the die set.

6. Insert two die retaining pins and the short die retaining screw into the ram plate, through the anvil die

and moving jaw. Tighten the screw just enough to hold the die in place. Do NOT completely tighten the

screw at this time.

7. Install the crimper die into the upper jaw of the crimp head. The die should be oriented so that the

chamfers are positioned to the left of the head assembly and the die markings are facing outward.

8. Insert two die retaining pins and the long die retaining screw into the upper jaw and through the

crimper die. Tighten the screw just enough to hold the die in place.

9. Replace the battery and check the die alignment by pulsing the trigger to slowly close the head,

making sure the anvil and indenter are properly aligned.

Figure 3

Pins

Short Die

Retaining Screw

Crimper Die

Anvil Die

Moving Jaw

Long Die

Retaining

Screw

Upper Jaw

Locator

Assembly

Nut Attaches to

End of Long Die

Retaining Screw

Ram Plate

Chamfer on

Ram Plate

Machine

Screw

NOTE

409- 10065

Rev F8of 9

10. When the dies are aligned, fully tighten the die retaining screws.

11. Install the locator assembly onto the long retaining screw and secure it with the appropriate hex nut.

3.2. Removal of Shouldered and Pinned Dies

To avoid personal injury, remove the battery before removing dies.

To remove dies from the crimp head, remove the die retaining screws, die retaining pins, ram plate, and slide

the dies out of the crimp head.

4. OPERATION

4.1. Battery Installation and Removal (Refer to Figure 1)

The Batteries Directive 2006/66/EC introduces new requirements from September 2008 on removability of batteries

from waste equipment in EU Member States. To comply with this Directive, this device is designed to allow the

rechargeable battery pack to be easily removed by the end--user when it needs to be replaced.

To install the battery, slide the battery into the bottom of the crimp tool until it can go no further. There will be an

audible “click” of the battery lock to indicate that the battery has been properly installed.

To remove the battery, disengage the battery lock by applying pressure on the lock toward the bottom of the

tool and slide the battery away from the tool.

Always dispose of the old battery pack in an environmentally--responsible way, in accordance with local waste

regulations. Where possible, please recycle the battery cartridge. Contact your local authority for details of battery

recycling locations in your area.

4.2. Crimping

The following procedure provides only general information concerning crimping. Refer to the instructions

packaged with the dies for detailed information, including wire stripping dimensions and instructions for

positioning terminals and splices in the dies.

To operate the SDE Battery Powered Crimp Tool 1213890--[ ]:

To avoid personal injury, keep fingers clear of the crimping area.

1. Insert the terminal into the dies.

2. Depress the trigger to advance the moving jaw in order to hold the terminal in place. Do NOT deform

the terminal body.

3. Place a pre--stripped wire in the barrel of the terminal.

4. Depress and hold the trigger to complete the crimp. The crimp tool returns automatically to the first

position of its cycle when the crimp is complete.

If it is necessary to retract the ram before a crimping cycle is completed, push the release switch. Pushing the release

switch will result in the complete retraction of the ram. Only kits 1213890--1, --2, and --5 have a release switch.

This tool is not designed for continuous operation. After 100 cycles, allow the crimp tool to cool for 15 minutes.

DANGER

NOTE

DANGER

NOTE

CAUTION

409- 10065

Rev F 9of 9

5. PREVENTIVE MAINTENANCE

5.1. Daily Maintenance

Perform the following maintenance on a daily basis:

1. Inspect the dies for wear or damage such as cracks, gouges, or chips.

2. Inspect the tool for damage or leaks. If damage is detected, return the tool to TE for repair.

3. Clean the tool, removing accumulations of dirt and grease on the head, particularly in areas where

dies are installed and terminals are crimped. Wipe the entire tool frequently with a clean, lint--free cloth.

5.2. Yearly Maintenance

Once a year, or every 10,000 cycles (whichever comes first), the SDE Closed Head Battery Powered Crimp

Tool should be returned to TE for inspection.

6. SPARE PARTS

SBattery: 1725839--1

SCharger: 1725840--1 (120 V, US), 1725840--2 (220 V, EU), 1725840--3 (220 V, UK)

7. TROUBLESHOOTING (Figure 4)

Prior to beginning troubleshooting procedures, be sure the battery is operational.

1. Be sure that the battery is charged. Recheck the battery after several minutes to ensure that the

battery is holding its charge.

2. Use a nonflammable contact cleaner or pencil eraser to clean the the electrical contacts on the

battery and crimp tool.

3. Reinstall the battery and check the crimp tool again.

PROBLEM PROBABLE CAUSE REMEDY

Dirt, contaminants, etc, in ram area of tool. Return tool to TE.

Tool is inoperative. Crimp tool battery contacts damaged. Reform the contacts.

Tool components are worn or damaged. Return tool to TE.

Oil level is low. Return tool to TE.

Dies stop during operation. Air in the hydraulic system.

Pull the trigger and hold the retract button

simultaneously. Hold for approximately 10

seconds.

Crimp tool loses oil. Damaged internal seal. Return tool to TE.

Figure 4

8. RETURN

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 (38--35)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105--3608

9. REVISION SUMMARY

Revisions to this customer manual include:

SUpdated document to corporate requirements

SAdded text to Section 4, OPERATION

Mouser Electronics

Authorized Distributor

Click to View Pricing, Inventory, Delivery & Lifecycle Information:

TE Connectivity:

1213890-4

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