“T”-HEAD* Battery-Powered Crimp Tool Kit

“T”-HEAD* Battery-Powered   Crimp Tool Kit
Customer Manual

“T”-HEAD* Battery-Powered
Crimp Tool Kit 1213803-[ ]
409-10061
05 JAN 12 Rev H
............................ 2
ORIGINAL INSTRUCTIONS
customer manual
SAFETY PRECAUTIONS READ THIS FIRST !
A.
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. RECEIVING/INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1. Battery Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2. Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. WIRE STRIPPING AND CRIMPING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1. PIDG* and PLASTI-GRIP* Terminals and Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2. Spare Wire Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. INSULATION CRIMP ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1. PIDG Terminals and Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2. PLASTI-GRIP Terminals and Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. CRIMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7. MAINTENANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2. Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.4. Gaging the Crimping Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10. RETURN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11. REVISION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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:
•
•
ALWAYS wear appropriate ear protection.
•
•
ALWAYS keep guard(s) in place during normal operation.
•
•
NEVER insert hands into installed application equipment.
ALWAYS wear approved eye protection when operating powered
equipment.
NEVER wear loose clothing or jewelry that may catch in moving parts of the
application equipment.
NEVER alter, modify, or misuse the application equipment.
© 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
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
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
1 of 16
LOC B
409-10061
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:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Customer name
Customer address
Person to contact (name, title, telephone number, and extension)
Person calling
Equipment number (and serial number if applicable)
Product part number (and serial number if applicable)
Urgency of request
Nature of problem
Description of inoperative component(s)
Additional information/comments that may be helpful
When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
DANGER
STOP
CAUTION
!
NOTE
i
NOTE
i
Rev H
Denotes an imminent hazard which may result in moderate or severe injury.


Denotes a condition which may result in product or equipment damage.


Highlights special or important information.


Dimensions in this manual are in metric units [with U.S. customary units in brackets].


2 of 16
409-10061
Rev H
3 of 16
409-10061
BATTERY TOOL KIT
REGION OF USE
BATTERY CHARGER
BATTERY CHARGER
VOLTAGE
RAM RETRACT
SWITCH
1213803-1
North America
1725840-1
110 V
Yes
1213803-2
Europe
1725840-2
220 V
Yes
1213803-3
North America
1725840-1
110 V
No
1213803-4
Europe
1725840-2
220 V
No
1213803-5
United Kingdom
1725840-3
220 V
Yes
Battery Lock
Battery Powered 
Crimp Tool
Battery Cartridge
1725839-1
Release Switch
(1213803-1, -2, and
-5 Only)
“T”-HEAD Adapter
Assembly
Trigger
“T-HEAD
Crimp Head
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)
1.5 kg [3.3 lb.]
Sound Level
75 dBA at 1 Meter
Vibration
< 2.5 m/s²
Hydraulic Oil
Shell Tellus‡ T 15
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
Rev H
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409-10061
1. INTRODUCTION
The "T"-HEAD Battery-Powered Crimp Tool Kit 1213803-[ ] consists of the battery-powered crimp tool (with the
"T"-HEAD Adapter 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 4. A battery tool may have a release switch to retract the ram as listed in the table
below. The "T"-HEAD Battery-Powered Crimp Tool Kit is designed to crimp PIDG and PLASTI-GRIP Terminals
on wire sizes 26-14 AWG, and Spare Wire Caps on wire sizes 22-14 AWG.
Refer to Figure 2 for product types and wire sizes.
PRODUCT
PIDG Insulation Restricting Terminals
MS 7928/1-1 through -10
PIDG Terminals MS 25036-143 through
-147 (Class 1 Only)
PIDG Radiation Resistant Terminals
MS 7928/4-143 through -147
PIDG Vinyl and PFTE Terminals and
Splices
Also PLASTI-GRIP 22-16 and 16-14
Terminals
PIDG Radiation Resistant Terminals
and Splices
AWG
WIRESIZ
E RANGE
WIRE INSUL
DIA RANGE
26
0.66-1.40
[.026-.055]
Yellow w/
Three
Black Stripes
24
0.79-1.40
[.031-.055]
Yellow w/
Three
Blue Stripes
One
Dot
26-24
----
One
Dot
22-16
Two
Dots
16-14
DOT
CODE
One
Dot
One
Dot
Two
Dots
INSULATION
COLOR
CODE
Yellow
Natural w/
Yellow Stripe
Red
---Blue
26-24 Terminals Only
22-16
16-14
WIRE STRIP LENGTH
TERMINALS
Min.
Max.
Min.
Max
6.35
[.250]
7.11
[.280]
-----
----
5.08
[.200]
5.84
[.230]
----
----
5.08
[.200]
5.84
[.230]
6.35
[.250]
7.11
[.280]
----
----
6.35
[.250]
7.11
[.280]
Natural w/
Yellow Stripe
----
Natural w/
Red Stripe
----
Natural w/
Blue Stripe
SPLICES
5.08
[.200]
5.84
[.230]
Figure 2
Rev H
5 of 16
409-10061
2. RECEIVING/INSPECTION
The "T"-HEAD Battery-Powered Crimp Tool Kit 1213803-[ ] 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 kit 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. OPERATION
3.1. Battery Installation and Removal (Refer to Figure 1)
NOTE
i
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.
DANGER 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
STOP
in your area.
3.2. Crimping
CAUTION Do not operate the tool without the "T"-HEAD adapter installed. Damage to the ram or seals can result.
!
"T"-HEAD Battery-Powered Crimp Tool Kit 1213803-[ ] comes with the "T"-HEAD adapter already installed on
the battery-powered hand tool. 
DANGER To avoid personal injury, be sure to exercise extreme caution when handling the crimp tool. Remove the battery before
installing or removing the crimp heads.
STOP
To operation the "T"-HEAD Powered Crimp Tool 1213803-[ ]:
1. Strip the wire to the dimensions shown in Figure 2.
2. Center the terminal or splice wire barrel in the appropriate crimp chamber.
3. Depress the trigger to advance the moving ram. This closes the crimp jaws in order to hold the terminal or
splice in place. Do NOT deform the terminal body.
4. Place a pre-stripped wire in the barrel of the terminal, making sure the wire insulation does not enter the
wire barrel.
Rev H
6 of 16
409-10061
5. 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.
CAUTION This tool is not designed for continuous operation. After 100 cycles, allow the crimp tool to cool for 15 minutes.
!
NOTE
Note that Figure 2 indicates the number of dots that appear embossed on a crimped terminal, splice or cap. Observe the
dot code on finished crimp to insure that correct product and tool combination was used.
i
NOTE
Dot code will disappear after heat sealing environment sealed splices.
i
NOTE
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 1213803-1, -2, and -5 have a release switch.
i
4. WIRE STRIPPING AND CRIMPING PROCEDURES
NOTE
Refer to Section 5 for insulation crimp adjustment.
i
CAUTION Do not re-terminate the splices or terminals.
!
4.1. PIDG and PLASTI-GRIP Terminals and Splices
1. Strip wire to dimensions listed in Figure 2.
NOTE
Do not use wires with nicked or missing conductor strands.
i
2. Crimp the color coded terminals and splices in the matching color coded portion of the tool. Refer to
Section 3.
3. Place terminal in crimping dies so that terminal tongue slides under locator. See Figure 3.
4. Raise locator and place splice under locator as shown in Figure 4. Splice window indent faces top of tool.
NOTE
To properly position pre-insulated sealed splice, apply and maintain pressure against end of splice until Step 5 is
completed. See Figure 4.
i
5. Depress trigger until terminal or splice is held firmly in place as shown in the crimping jaws. Do not deform
terminal or splice wire barrel.
6. Insert stripped wire into terminal until conductor butts against locator. See Figure 3. Insert stripped wire into
splice until conductor butts against splice wire stop. See Figure 4.
Rev H
7 of 16
409-10061
Figure 3
NOTE
Do not allow wire insulation to enter wire barrel.
i
7. Hold wire in position and complete crimp by depressing the trigger until the crimp is complete.
8. Repeat steps 1 through 7 to perform the second crimp on a butt splice. See Figure 4.
9. Refer to Section 6 and Figure 6 or Figure 7 for terminal or splice "Crimp Inspection" procedure.
4.2. Spare Wire Caps
1. Strip wire to dimensions listed in Figure 2. Crimp the color coded portion of the tool. Refer to Section 3.
NOTE
Do not use wire with nicked or missing conductor strands.
i
2. Place tool insulation adjustment indicator in Position 4.
3. Depress trigger until crimping jaws partially close, but leave enough space for cap to be inserted between
dies.
4. Raise locator so that end of cap rests against the recessed surface of the locator as shown in Figure 5.
5. Depress trigger and close crimp jaws until cap is held firmly in place. Do not deform cap wire barrel.
6. Insert stripped wire into cap until conductor bottoms in cap.
7. Hold wire in position and complete crimp by depressing the trigger until the crimp is complete.
8. Refer to Section 6 and Figure 7 for wire cap crimp inspection procedure.
Rev H
8 of 16
409-10061
Figure 4
Rev H
9 of 16
409-10061
Figure 5
Rev H
10 of 16
409-10061
Figure 6
5. INSULATION CRIMP ADJUSTMENT
5.1. PIDG Terminals and Splices
NOTE
PIDG terminals and splices feature a wire "insulation grip."
i
Each tool has four insulation crimp positions.
1. Loosen insulation adjustment locking screw (see top of tool) and turn indicator to Position 4.
2. Place terminal or splice in tool dies.
3. Insert UNSTRIPPED wire into ONLY the insulation barrel (see Figure 3 or Figure 4) of terminal or splice.
Rev H
11 of 16
409-10061
4. Perform a crimp (Section 4). Remove crimped terminal or splice and check insulation grip as follows: Bend
the wire back and forth once. Terminal or splice should retain grip on wire insulation.
5. If wire pulls out, set insulation adjustment indicator to next tighter position - Position 3.
6. Perform a crimp and repeat adjustment as necessary until desired insulation grip is obtained. Do not use a
tighter setting than required.
7. Tighten insulation adjustment locking screw (see top of tool).
Figure 7
Rev H
12 of 16
409-10061
5.2. PLASTI-GRIP Terminals and Splices
NOTE
PLASTI-GRIP terminals and splices feature a wire "insulation support" only.
i
1. Set insulation adjustment indicator in Position 4 for wire having a large insulation diameter.
2. Set insulation adjustment indicator in Position 3 for wire having a medium insulation diameter.
3. Set insulation adjustment indicator in Position 2 for wire having a small insulation diameter.
4. Set insulation adjustment indicator in Position 1 for wire having thin wall insulation. Terminal or splice
insulation should ideally be in contact with wire insulation.
6. CRIMP INSPECTION
Inspect crimped terminals, splices and spare wire caps by checking the features described in Figure 6 or 
Figure 7.
Use only the crimped items that meet the conditions shown in the ACCEPT column.
REJECT terminals, splices, and spare wire caps can be avoided through careful use of instructions and by
performing regular tool maintenance as instructed in this document.
7. MAINTENANCE AND INSPECTION
TE recommends that a maintenance/inspection program be performed periodically to ensure dependable and
uniform terminations. Tools should be inspected at least once a month. Frequency of inspection may be
adjusted to suit certain requirements through experience. Frequency of inspection is dependent upon:
1. The care, amount of use, and handling of the tool.
2. The type and size of the products crimped.
3. The degree of operator skill.
4. The presence of abnormal amounts of dust and dirt, and
5. User established standards.
All tools are inspected before packaging. Since there is a possibility of tool damage in shipment, new tools
should be inspected in accordance with Section 7 upon arrival. Due to the precision design, it is important that
no parts of these tools be interchanged.
7.1. Cleaning
Clean the tool, removing accumulations of dirt and grease on the head, particularly in areas where terminals are
crimped. Wipe the tool frequently with a clean, lint-free cloth.
7.2. Visual Inspection
1. Visually inspect the tool for missing parts, then operate the tool and note the return action of the tool.
2. Visually inspect the die closure surfaces for flattened, broken, pitted, or chipped conditions. Although dies
may gage within permissible limits, worn or damaged die closure surfaces are objectionable and can affect
the quality of the crimp. Examples of possible damaged die closure surfaces are shown in Figure 8.
7.3. Lubrication
Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as follows:
•
•
•
Tools used in daily production-Lubricate daily
Tools used daily (occasional)-Lubricate weekly
Tools used weekly-Lubricate monthly
Wipe excess oil from tool, particularly from crimping area. Oil transferred from the crimping area onto certain
terminations may affect the electrical characteristics of an application.
Rev H
13 of 16
409-10061
Broken Corner
Flattened
Chipped Edge
Pitted
Figure 8
7.4. Gaging the Crimping Chamber
Each tool is inspected for proper die closures before packaging. An inspection should be performed periodically
to check the tool die closures for excessive wear.
NOTE
i
The following plug gaging information for insulation crimping chambers is provided for customers specifically requiring this
information. If plug gaging is not required, inspect the die closures using an alternate procedure, i.e., performing the
"Insulation Crimp Adjustment" (see Section 5) and "Visual Inspection" (see Paragraph 7.2).
This inspection requires the use of plug gages conforming to the dimensions listed in Figure 9 and Figure 10. TE
does not manufacture or market these gages. Refer to 408-7424 for ordering information and care of gages.
AWG WIRE SIZE RANGE
GAGE ELEMENT DIMENSION “B"
GO
NO-GO
22 - 16
2.769-2.776 [.1090-.1093]
2.918-2.921 [.1149-.1150]
16 - 14
3.023-3.030 [.1190-.1193]
3.172-3.175 [.1249-.1250]
Figure 9
To gage the crimping area(s), refer to Figure 11 and proceed as follows:
1. Clean oil or dirt from the crimping chamber and plug gage.
2. Depress the trigger of the tool to advance the ram until the wire barrel dies bottom. Do NOT continue to
depress the trigger once the dies have bottomed.
Rev H
14 of 16
409-10061
AWG WIRE SIZE RANGE
GAGE ELEMENT DIMENSION “D"
GO
NO-GO
22 - 16
0.762-0.770 [.0300-.0303]
2.791-2.794 [.1099-.1100]
16 - 14
1.016-1.024 [.0400-.0403]
3.045-3.048 [.1199-.1200]
WIDTH “W" (Max.)
3.18 [.125]
Figure 10
3. With wire barrel dies bottomed, inspect the wire barrel crimping chamber using the proper plug gage. Lift
the spring-loaded locator and hold gage in straight alignment with the crimping chamber. Carefully try to
insert, without forcing, the GO element. See Figure 11, Detail A. The GO element must pass completely
through the crimping area.
4. Try to insert the NO-GO element. The NO-GO element may enter partially, but must not pass completely
through the crimping area.
5. Set insulation adjustment indicator in Position 1. Measure both insulation crimping chambers with the
proper GO plug gages in the same manner as Steps 2 and 3. See Figure 11, Detail B.
6. Set insulation adjustment indicator in Position 4. Measure both insulation crimping chambers with the
proper NO-GO plug gages in the same manner as Steps 2 and 4. See Figure 11, Detail B.
If the crimping areas conform to the gage inspection, the tool is considered dimensionally correct. If the crimping
areas do not conform to the inspection, the tool must be repaired. Refer to Section 8, REPLACEMENT AND
REPAIR.
Figure 11
Rev H
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409-10061
8. SPARE PARTS
•
•
Battery: 1725839-1
Charger: 1725840-1 (120 V, US), 1725840-2 (220 V, EU), 1725840-3 (220 V, UK)
9. TROUBLESHOOTING (Figure 12)
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
Tool is inoperative.
Dies stop during operation.
Crimp tool loses oil.
PROBABLE CAUSE
REMEDY
Dirt, contaminants, etc, in ram
area of tool.
Return tool to TE.
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.
Air in the hydraulic system.
Pull the trigger and hold the
retract button simultaneously.
Hold for approximately 10
seconds.
Damaged internal seal.
Return tool to TE
Figure 12
10. 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 (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
11. REVISION SUMMARY
•
Used PTFE as a descriptive identifier.
Rev H
16 of 16
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