TE Connectivity 1901343 Series Reference guide

409--10070

Customer Manual

Latch Head

1of 8

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 D

Battery Powered Crimp

Tool Kit 1901343- [ ]

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

SAFETY PRECAUTIONS

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

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

3. INSTALLATION OF DIES 5.............................................

3.1. Installation of Die Assemblies 5......................................

3.2. Removal of Die Assemblies 6........................................

4. OPERATION 6......................................................

4.1. Battery Installation and Removal 6....................................

4.2. Crimping 7.....................................................

5. PREVENTIVE MAINTENANCE 8........................................

5.1. Daily Maintenance 8..............................................

5.2. Yearly Maintenance 8..............................................

6. ADJUSTMENTS 8....................................................

7. ADJUSTMENTS 8....................................................

8. TROUBLESHOOTING 8...............................................

9. REVISION SUMMARY 8...............................................

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- 10070

Rev D2of 8

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- 10070

Rev D 3of 8

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

409- 10070

Rev D4of 8

Release Switch

(1901343--1 and

-- 2 O n l y )

Battery Lock

Battery Cartridge

1725839--1

Battery Powered

Crimp Tool

Latch Head

Adapter Assembly

Yoke

Latch Arm

Locking Flange

CRIMPING TOOL (with Battery Installed)

Length 356 mm [14 In.]

Width 60 mm [2 3/8 In.]

Depth 80 mm [3 1/8 In.]

Mass/Weight (w/Battery) 1.6kg[3.5lb.]

Sound Level 75 dBA at 1 Meter

Vibration <2.5m/s2

Hydraulic Oil Shell TellusT15

CRIMPING CAPACITIES

Maximum Crimping Force 35 kN [4 Tons]

Average Crimping Time 4 Seconds

Average Crimps Per Charge Approximately 85

BATTERY

Charging Voltage 9.6 V

Charging Time 40 Min

Figure 1

409- 10070

Rev D 5of 8

1. INTRODUCTION

Latch Head Battery Powered Crimp Tool Kit 1901343--[ ] consists of the Latch Head Battery Powered Crimp

Tool (with the Latch Head Assembly installed), as well as two rechargeable battery cartridges (1725839--1) to

power the tool. See Figure 1. Kits 1901343--1 and --3 include a 110V battery charger (1725840--1); Kits

1901343--2 and --4 include a 220V battery charger (1725840--2). Kits 1901343--1 and --2 have a release switch

to retract the ram. Kits 1901343--3 and --4 do not have a release switch. The Latch Head Battery Powered

Crimp Tool is designed to accept interchangeable die assemblies for crimping various types of connectors.

2. RECEIVING/INSPECTION

Latch Head Battery Powered Crimp Tool Kit 1901343--[ ] is thoroughly inspected during and after assembly.

Prior to packaging and shipping a final series of tests and inspections is made to ensure proper functioning 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 DIE ASSEMBLIES

Do no operate the tool without the Latch Head Installed. Damage to the ram or seals can result.

Do not operate the tool without the die assemblies. Damage to the crimp head can result.

Latch Head Battery Powered Crimp Tool 1901343--[ ] comes with the crimp head already installed on the

battery--powered hand tool. The only installation required is the installation of the die assemblies.

To avoid personal injury, be sure to exercise extreme caution when handling the crimp tool. Avoid accidentally

depressing the trigger control when installing or removing crimp dies.

3.1. Installation of Die Assemblies (Figure 2A )

These instructions are specific to the use of TE Die Assemblies. Be sure to use ONLY TE Die Assemblies.

1. With the battery installed, extend the ram until the ram setscrew is visible.

2. Remove the battery from the tool.

3. Loosen the setscrew in the ram.

4. Insert the shank of the moving die into the ram, and tighten the setscrew.

5. Pivot the latch arm away from the yoke to open up the crimp head.

6. Loosen the setscrew in the yoke.

7. Insert the shank of the stationary die into the yoke, and tighten the setscrew.

CAUTION

DANGER

CAUTION

409- 10070

Rev D6of 8

To avoid damage to the dies, be sure that the moving and stationary dies are properly oriented.

8. Replace the battery and activate the power unit to allow the ram to return to the “down” position.

9. Pivot the yoke toward the latch arm until the locking flange secures the latch arm to the yoke.

Always make sure the yoke and latch arm are secured by the locking flange before cycling the tool to crimp the

product.

3.2. Removal of Die Assemblies (Figure 2B)

To avoid personal injury, do not accidentally depress the trigger while removing the dies.

1. Pivot the latch arm away from the yoke to open the head.

2. Extend the ram until the ram setscrew is visible.

3. Remove the battery from the tool.

4. Loosen the setscrew in the yoke, and remove the stationary die.

5. Loosen the setscrew in the ram, and remove the moving die.

Figure 2

Latch Arm

Yoke Setscrew

2A 2B

Moving Dies Extended

Stationary Dies

Yoke Setscrew

Yoke

Ram Setscrew

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.

CAUTION

DANGER

NOTE

409- 10070

Rev D 7of 8

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 die assemblies.

Operation of Latch Head Battery Powered Crimp Tool 1901343--[ ] consists of:

Avoid personal injury. When operating tool or power unit, exercise caution while holding terminals or wire near the

crimping area.

1. Strip the wire to the dimensions provided for the terminals in TE Instruction Sheets 408--10050

(SOLISTRAND* Terminals and Splices); or 408--10051 (TERMINYL*, AMPOWER*, PLASTI--GRIP*

Terminals and Splices). Do not nick or cut the wire strands.

2. Select the proper color--coded terminal for the wire size. The wire size stamped on the terminal

tongue and on the crimping die must match the wire size selected.

3. Insert stripped wire fully into the terminal wire barrel.

Do NOT turn or twist the wire or terminal during insertion.

4. Pivot the latch arm away from the yoke to open the head.

5. Place the terminal in the stationary die.

6. Holding the terminal in place, pivot the yoke and latch arm toward each other until the locking flange

secures the latch arm to the yoke.

Always make sure the yoke and latch arm are secured by the locking flange before cycling the tool to crimp the

product.

7. Holding the wire in place, activate the tool to complete the crimp.

8. When the crimp is completed, pivot the latch arm away from the yoke to open the head and remove

the terminal.

If the terminal sticks in the die after crimping, apply a rocking action to the terminal to remove it from the die. Wipe

light oil on the dies to prevent sticking, or use spray dry lubricant.

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 1901343--1 and --2 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

CAUTION

NOTE

CAUTION

409- 10070

Rev D8of 8

9. Inspect the crimp according to the crimping procedures for the terminals provided in TE Instruction

Sheets 408--10050 (SOLISTRAND Terminals and Splices); or 408--10051 (TERMINYL, AMPOWER,

PLASTI--GRIP Terminals and Splices).

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 Latch 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 3)

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. Clean the tool.

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.

es stop

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 3

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

P.O. BOX 3608

HARRISBURG, PA 17105--3608

9. REVISION SUMMARY

SUpdated document to corporate requirements

SAdded text to Section 4, OPERATION

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