CERTI- CRIMP* II Battery Powered
Crimp Tool Kit 1213805- [ ]
Customer Manual
409--10055
13 JUL 11 Rev F
SAFETY PRECAUTIONS
READ THIS FIRST ! 2.........................
1. INTRODUCTION 4...................................................
2. RECEVING/INSPECTION 5.............................................
3. INSTALLATION AND REMOVAL OF CRIMPING HEADS 5......................
3.1. Installation of Crimping Heads 5......................................
3.2. Removal of Crimping Heads 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. Y early Maintenance 7..............................................
6. SPARE PARTS 7....................................................
7. TROUBLESHOOTING 7...............................................
8. REPLACEMENT AND REPAIR 7.........................................
9. RoHS INFORMATION 8...............................................
ORIGINAL INSTRUCTIONS
10. REVISI ON 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:
D ALWAYS wear appropriate ear protection.
D ALW AYS wear appropriate eye protection.
D ALW AYS wear approved eye protection when operating powered equipment.
D ALW AYS 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.
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
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- -8 00 --722 --1111
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com
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LOC B
SAFETY PRECAUTIONS - - IMPORTANT SAFETY INFORMATION
409- 10055
DANGER
DANGER
DANGER
CAUTION
CAUTION
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.
CAUTION
CAUTION
NOTE: Keep all decals clean and legible, and replace
when necessary.
Rev F2 of 8
409- 10055
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1 - 800 - 722 - 1111 (CONTINENTAL UNITED STATES AND PUERTO RI CO 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
Rev F 3 of 8
Quick--Release
Pin 217873--2
(Recommended
Spare)
409- 10055
Battery Lock
Battery Powered
Crimp Tool
Release Switch
(1213805--1, --2,
and --5 Only)
Battery
Cartridge
1725839--1
Trigger
SDE Adapter
Quick--Release
Pins 217873--1
Typical Crimping
Head (Ref)
CRIMPING TOOL (with Battery Installed)
Length 305 mm [12 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 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
(Recommended
Spare)
Figure 1
1. INTRODUCTION
The CERTI--CRIMP II Battery Powered Crimp Tool Kit 1213805-- [ ] is comprised of the battery crimp tool (with
the SDE Hand Tool 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 below. A battery tool may have a release switch to retract the ram as
listed in the table below. The CERTI--CRIMP II Battery Powered Crimp Tool Kit is designed to adapt the
crimping head from any CERTI--CRIMP II straight action hand tool (SAHT) for use with the battery powered
Rev F4 of 8
409- 10055
crimp tool. For crimp head information (including wire preparation, crimping procedures, maintenance and
inspection procedures, as well as repair and replacement procedures) refer to the appropriate instruction sheet
for the associated hand tool and crimping head.
BATTERY TOOL KIT REGION OF USE BATTERY CHARGER
1213805--1 North America 1725840--1 110 V Yes
1213805--2 Europe 1725840--2 220 V Yes
1213805--3 North America 1725840--1 110 V No
1213805--4 Europe 1725840--2 220 V No
1213805--5 United Kingdom 1725840--3 220 V Yes
BATTERY CHARGER
VOLTAGE
RAM RETRACT
SWITCH
2. RECEIVING/INSPECTION
The CERTI--CRIMP II Battery Powered Crimp Tool Kit 1213805--[ ] 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. INSTALLATION/REMOV AL OF CRIMPING HEADS
CAUTION
Do not operate the tool without the SDE hand tool adapter Installed. Damage to the ram or seals can result.
!
CAUTION
Do not operate the tool without a hand tool crimp head installed. Damage to the adapter can result.
!
CERTI--CRIMP II Battery Powered Crimp Tool Kit 1213805--[ ] comes with SDE hand tool adapter already
installed on the battery powered hand tool. The only installation required is the installation of the crimping
heads.
DANGER
3.1. Installation of Crimping Heads
As supplied, the adapter has three quick--release pins installed (Figure 1). The two outer pins will be used to
secure the two outer housing tabs of the crimp head (exposed portion of the crimp head) to the adapter. The
center pin will be used to secure the movable die of the crimp head to the ram of the adapter.
These pins must be removed prior to installing the crimping head.
T o avoid personal injury, be sure to exercise extreme caution when handling the crimp tool. Remove the battery before
installing or removing crimping heads.
1. Remove the battery from the tool.
2. Remove the quick--release pins, described above.
3. Insert the exposed portion of the crimp head into the adapter cavity. See Figure 1.
Rev F 5 of 8
409- 10055
4. Insert the two outer quick--release pins through the holes in the adapter, and through the holes in the
two outer tabs of the crimping head.
NOTE
The quick--release pins will “snap” into position when they are properly inserted.
i
5. Insert the center quick--release pin into the adapter and through the holes in the ram and the
moveable die of the crimp head.
NOTE
The quick--release pin will “snap” into position when it is properly inserted.
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3.2. Removal of Crimping Heads
DANGER
To remove the crimping head, it will be necessary to remove the quick--release pins and the crimp head from
the battery powered crimp tool.
4. OPERATION
4.1. Battery Installation and Removal (Refer to Figure 1)
NOTE
i
T o avoid personal injury, remove the battery before removing the crimping heads.
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 in your area.
4.2. Crimping
The following procedure provides only general information concerning crimping. Refer to the instructions
packaged with the crimping head for detailed information, including wire stripping dimensions and instructions
for positioning terminals and splices in the crimpers.
To operate the CERTI--CRIMP II Battery Powered Crimp Tool 1213805--[ ]:
DANGER
T o avoid personal injury, keep fingers clear of the crimping area.
1. Insert the contact into the dies.
2. Depress the trigger to advance the moving jaw in order to hold the contact in place. Do NOT deform
the insulation barrel or wire barrel.
3. Place a pre--stripped wire in the barrel of the contact.
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.
Rev F6 of 8
409- 10055
p
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 1213805--1, --2, and --5 have a ratchet release switch.
i
CAUTION
!
5. PREVENTIVE MAINTENANCE
5.1. Daily Maintenance
Perform the following maintenance on a daily basis:
5.2. Yearly Maintenance
Once a year, or every 10,000 cycles (whichever comes first) The CERTI--CRIMP II Battery Powered Crimp
Tool should be returned to TE for inspection.
6. SPARE PARTS
S Battery: 1725839-- 1
S Charger: 1725840--1 (120 V, US), 1725840--2 (220 V, EU), 1725840--3 (220 V, UK)
This tool is not designed for continuous operation. After 100 cycles, allow the crimp tool to cool for 15 minutes.
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 adapter, particularly in areas where
heads are installed and contacts are crimped. Wipe the entire tool frequently with a clean, lint--free cloth.
7. TROUBLESHOOTING (Figure 2)
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 Return tool to TE.
Tool is inoperative.
Dies stop during operation.
Crimp tool loses oil. Damaged internal seal. Return tool to TE.
Crimp tool battery contacts damaged
Tool components are worn or damaged. Return tool to TE.
Oil level is low. Return tool to TE.
Air in the hydraulic system.
Figure 2
Reform the contacts.
Pull the trigger and hold the retract button
simultaneously. Hold for approximately 10
seconds.
8. REPLACEMENT AND REPAIR
DANGER
To avoid personal injury, ALWAYS remove the battery cartridge from the tool BEFORE performing any maintenance on
the tool.
Replacement parts are identified in Figure 1. The recommended spares should be stocked for immediate
replacement. Order replacement parts (or return parts) through your TE Representative, or call
1--800--526--5142, or send a facsimile of your purchase order to 717--986-- 7605. Or write to:
Rev F 7 of 8
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
409- 10055
NOTE
For replacement parts for crimping heads, refer to the instruction sheets packaged with the specific heads.
i
9. RoHS INFORMATION
Information on the presence and location of any substances subject to RoHS (Restriction on Hazardous
Substances) can be found at the following website:
http://www
Click on “Find Compliance Status” and enter equipment part number.
10. REVISION SUMMARY
.te.com/customersupport/rohssupportcenter/
S Updated document to corporate requirements
S Added new text to Section 4, OPERATION
Rev F8 of 8
Mouser Electronics
Authorized Distributor
Click to View Pricing, Inventory, Delivery & Lifecycle Information:
TE Connectivity:
1213805-4
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