TE Connectivity 1213875 Series User manual

© 2014 TE Connectivity 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.
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
1of 5
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
i
DANGER
STOP
!
CAUTION

408-10231
3of 5
Rev D
Figure 3

408-10231
4of 5
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
i
DANGER
STOP

408-10231
5of 5
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).