TE Connectivity 1213819-1 Reference guide

409--10058
Customer Manual
Straight- Action Adapter Battery
1of 8
LOC B
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
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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 E
Powered Crimp Tool Kit 1213819- [ ]
READ THIS FIRST ! 2.........................
SAFETY PRECAUTIONS
1. INTRODUCTION 4...................................................
2. RECEVING/INSPECTION 5.............................................
3. DIE INSTALLATION AND REMOVAL 5....................................
3.1. Die Set Installation 6..............................................
3.2. Die Set Removal 6...............................................
4. OPERATION 6......................................................
4.1. Battery Installation and Removal 6....................................
4.2. Crimping 6.....................................................
5. PREVENTIVE MAINTENANCE 7........................................
5.1. Daily Maintenance 7..............................................
5.2. Yearly Maintenance 7..............................................
6. SPARE PARTS 7....................................................
7. TROUBLESHOOTING 7...............................................
8. RETURN/REPAIR 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.
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

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SAFETY PRECAUTIONS - - IMPORTANT SAFETY INFORMATION
DANGER
DANGER
DANGER
DANGER
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
CAUTION
CAUTION
CAUTION

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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
1213819--1 North America 1725840--1 110 V Yes
1213819--2 Europe 1725840--2 220 V Yes
1213819--3 North America 1725840--1 110 V No
1213819--4 Europe 1725840--2 220 V No
1213819--5 United Kingdom 1725840--3 220 V Yes

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Figure 1
Release Switch
(1213819--1, --2,
and --5 Only)
Battery Powered
Crimp Tool
Battery
Lock
Battery
Cartridge
1725839--1
Trigger
Moving Die
Holder
Stationary Die
Holder
Straight--Action
Adapter
1. INTRODUCTION
Straight--Action Adapter Battery Powered Crimp Tool Kit 1213819--[ ] consists of the battery powered crimp tool
(with the Straight--Action Adapter 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 on Page 3. A battery tool may have a release
switch to retract the ram as listed in the table below. The Straight--Action Adapter Battery Powered Crimp Tool
Kit 1213819--[ ] is designed to accept various crimping die assemblies that are sold separately and are
available from TE Connectivity. For crimping die set information concerning wire preparation, crimping
procedures, maintenance, inspection, and repair, refer to the applicable instructions for the appropriate
crimping die set.
Specifications are listed in Figure 2.

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CRIMP TOOL (with Battery Installed)
Length 343 mm [13.5 In.]
Width 60 mm [2 3/8 In.]
Depth 80 mm [3 1/8 In.]
Mass/Weight (w/Battery) 1.3kg[2.9lb.]
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 2
2. RECEIVING/INSPECTION
The Straight--Action Battery Powered Crimp Tool Kit 1213819--[ ] 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 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. DIE INSTALLATION AND REMOVAL
Do not operate the tool without the Straight--Action Adapter installed. Damage to the ram or seals can result.
Do not operate the tool without a die set installed. Damage to the adapter can result.
Straight--Action Adapter Battery Powered Crimp Tool Kit 1213819--[ ] comes with the straight--action adapter
assembly already installed on the battery--powered hand tool. The only installation required is the installation of
the dies.
To avoid personal injury, be sure to exercise extreme caution when handling the crimp tool. Remove the battery before
installing or removing the dies.
CAUTION
!
CAUTION
!
DANGER

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3.1. Die Set Installation (Figure 3 )
If dies to be installed in the tool require insulation adjustment, refer to the instruction sheet packaged with the
dies for adjustment, then proceed as follows:
1. Remove the battery from the tool.
2. Mate the die assembly and insert it into the tool yoke. See Figure 3.
3. Position the stationary die in the stationary die holder. Turn the die retaining screw sufficiently to hold
the die in place. Do not tighten the screw.
4. Position the moving die in the moving die holder. Turn the die retaining screw sufficiently to hold the
die in place. Do not tighten the screw.
5. Replace the battery and check the alignment by pulsing the trigger to (slowly) close the dies, making
sure the anvil and indenter are properly aligned.
6. With the dies closed, tighten the die retaining screws.
Figure 3
Moving
Die
Color Code
Stationary
Die
Locator Die Retaining Screw
Dies Installed in Tool Yoke
3.2. Die Set Removal
To remove or change the dies, simply loosen the die retaining screws and remove the dies.
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.
NOTE
i
DANGER

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To avoid personal injury, keep fingers clear of the crimping area.
To operate the Straight--Action Adapter Battery Powered Crimp Tool 1213819--[ ]:
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 1213819--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.
5. PREVENTIVE MAINTENANCE
5.1. Daily Maintenance
Perform the following maintenance on a daily basis:
1. Inspect the die set, adapter assembly for wear or damage such as cracks, gouges, or chips.
2. Inspect the crimp 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 the
dies are installed and terminals are crimped. Wipe the entire tool frequently with a clean, lint--free cloth.
DO NOT use objects that could damage the tool.
4. Make sure that the die retaining screws are in place and are tight.
5.2. Yearly Maintenance
Once a year, or every 10,000 cycles (whichever comes first) The Straight--Action Adapter 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.
DANGER
NOTE
i
CAUTION
!

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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.
p
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
SUpdated document to corporate requirements
SAdded new text to Section 4, OPERATION

Mouser Electronics
Authorized Distributor
Click to View Pricing, Inventory, Delivery & Lifecycle Information:
TE Connectivity:
1213819-3