Tyco 1213890 Series Reference guide

409-10065
Customer Manual
DE Closed Head
1 of 8
LOC B
E 2006 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
Tyco is a trademark. *Trademark
Other products, logos, and company names used are the property of their respective owners.
This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
For latest revision or Regional Customer Service, visit
our website at www.tycoelectronics.com
13 APR 06 Rev B
Battery Powered Crimp
Tool Kit 1213890-[ ]
READ THI FIR T ! 2...........................
SAFETY PRECAUTIONS
1. INTRODUCTION 5....................................................
2. RECEIVING/IN PECTION 5.............................................
3. IN TALLATION/REMOVAL OF DE CRIMP DIE 5............................
3.1. Installation of SDE Crimp Dies 5.......................................
3.2. Removal of Shouldered and Pinned Dies 7...............................
4. OPERATION 7.......................................................
5. PREVENTIVE MAINTENANCE 8.........................................
5.1. Daily Maintenance 8...............................................
5.2. early Maintenance 8..............................................
6. TROUBLE HOOTING 8................................................
7. RETURN 8..........................................................
8. REVI ION UMMARY 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:
D ALWAYS wear appropriate ear protection.
D ALWAYS wear appropriate eye protection.
D ALWAYS wear approved eye protection when operating powered equipment.
D ALWAYS keep guard(s) in place during normal operation.
D NEVER wear loose clothing or jewelry that may catch in moving parts of the
application equipment.
D NEVER insert hands into installed application equipment.
D NEVER alter, modify, or misuse the application equipment.
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409-10065
SDE Clos d H ad Batt ry Pow r d Crimp Tool Kit 1213890-[ ]
Rev B2 of 8
SAFETY PRECAUTIONS -- IMPORTANT SAFETY INFORMATION
CAUTION
CAUTION
CAUTION
CAUTION
DANGER
DANGER
DANGER
DANGER
DANGER
DANGER

409-10065
SDE Clo ed Head Battery Powered Crimp Tool Kit 1213890-[ ]
Rev B 3 of 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 Engineers 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:
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if applicable)
6. Product part number (and serial number if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that may be helpful

409-10065
SDE Closed Head Battery Powered Crimp Tool Kit 1213890- ]
Rev B4 of 8
DE Crimp Die
Location
Release witch
(1213890-1 and
-2 Only)
Battery
Lock
Battery
Cartridge
1725839-1
Battery Powered
Crimp Tool
DE 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) 1.5 kg [3.4 lb.]
ound Level 75 dBA at 1 Meter
Vibration < 2.5 m/s2
Hydraulic Oil hell Tellus  T15
CRIMPING CAPACITIES
Maximum Crimping Force 15.6 kN [1.75 Tons]
Average Crimping Time 2 econds
Average Crimps Per Charge Approximately 150
BATTERY
Charging Voltage 9.6 V
Charging Time 40 Min
Figure 1

409-10065
SDE Closed Head Battery Powered Crimp Tool Kit 1213890-[ ]
Rev B 5 of 8
1. INTROD CTION
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. Kits 1213890–1 and –3 include a 110V battery charger
(1725840–1); Kits 1213890–2 and –4 include a 220V battery charger (1725840–2). Kits 1213890–1 and –2
have a release switch to retract the ram. Kits 1213890–3 and –4 do not have a release switch. The SDE
Closed Head Battery Powered Crimp Tool is designed to accept interchangeable die assemblies used in
PRO–CRIMPER hand 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
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 Tyco Electronics 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.
3. INSTALLATION/REMOVAL OF SDE CRIMP DIES
Do not ope ate the tool without the SDE C imp Head Installed. Damage to the am o seals can esult.
Do not ope ate the tool without the SDE dies. Damage to the c imp head can esult.
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 pe sonal inju y, be su e to exe cise ext eme caution when handling the c imp tool. Avoid accidentally
dep essing the t igge cont ol when installing o emoving c imp dies.
3.1. Installation of SDE Crimp Dies
These inst uctions a e specific to the use of Tyco Elect onics SDE C imp Dies. Be su e to use ONLY Tyco Elect onics
C imp Dies.
The SDE Batte y Ope ated C imp Tool cannot be used to c imp pa allel splices.
A. Installation of Shouldered Dies (Figure 2 )
1. Remove the two die retaining screws from the crimp head.
2. Remove the ram plate from the moving jaw.
3. Place the upper die in the upper portion of the tool head so that the largest indenter is on the right.
4. 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.
5. Place the lower die in the moving jaw of the crimp head so that the largest anvil is on the right.
6. 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.
7. 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.
CA TION
CA TION
DANGER
CA TION
NOTE

409-10065
SDE C osed Head Battery Powered Crimp Too Kit 1213890-[ ]
Re B6 of 8
8. Pulse the trigger to slowly close the crimp head, making sure the anvils and indenters are properly
aligned.
9. 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
Mo ing Jaw
Upper Jaw
Ram Plate
Machine Screw
Chamfer on
Ram Plate
B. Insta ation of Pinned Dies (Figure 3)
1. 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.
2. Remove the ram plate from the moving jaw.
3. 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.
4. 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.
5. 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.
6. 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.
7. 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.
8. Check the die alignment by pulsing the trigger to slowly close the head, making sure the anvil and
indenter are properly aligned.
9. When the dies are aligned, fully tighten the die retaining screws.
10. Install the locator assembly onto the long retaining screw and secure it with the appropriate hex nut.
NOTE

409-10065
SDE Closed He d B ttery Powered Crimp Tool Kit 1213890-[ ]
Rev B 7 of 8
Figure 3
Pins
Short Die
Retaining Screw
Crimper Die
Anvil Die
Moving Jaw
Long Die
Retaining
Screw
Upper Jaw
Locator
Assembly
N t Attaches to
End of Long Die
Retaining Screw
Ram Plate
Chamfer on
Ram Plate
Machine
Screw
3.2. Remov l of Shouldered nd Pinned Dies
To avoid ersonal injury, do not accidentally de ress the trigger while 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
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.
Operation of SDE Battery Powered Crimp Tool 1213890–[ ] consists of:
To avoid ersonal injury, kee fingers clear of the crim ing 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. Hold the trigger down 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 crim ing cycle is com leted, ush the release switch. Pushing the release
switch will result in the com lete retraction of the ram. Only kits 1213890-1 and -2 have a release switch.
This tool is not designed for continuous o eration. After 100 cycles, allow the crim tool to cool for 15 minutes.
DANGER
DANGER
NOTE
CAUTION

409-10065
SDE Closed Head Battery Powered Crimp Tool Kit 1213890-[ ]
Rev B8 f8
5. PRE ENTI E 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 Tyco Electronics 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 Tyco Electronics for inspection.
6. 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, c ntaminants, etc, in ram area f t l. Clean the t l.
T l is in perative. Crimp t l battery c ntacts damaged. Ref rm the c ntacts.
T l c mp nents are w rn r damaged. Return t l t Tyc Electr nics.
Oil level is l w. Return t l t Tyc Electr nics.
Dies st p during perati n. Air in the hydraulic system. Pull the trigger and h ld the retract butt n
simultane usly. H ld f r appr ximately 10
sec nds.
Crimp t l l ses il. Damaged internal seal. Return t l t Tyc Electr nics.
Figure 4
7. RETURN
Order replacement parts through your Tyco Electronics 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
8. RE ISION SUMMARY
S Updated document to corporate requirements
S Added new part number to Figure 1
S Added new text to Sections 1 and 4