TE Connectivity 2217480 Series Referenzhandbuch

Customer Manual

1 of 9

*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.

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.

409-32031

07 AUG 17 Rev D

SAFETY PRECAUTIONS —READ THIS FIRST! .....................................................................2

SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!......................................3

1. INTRODUCTION ..................................................................................................................4

2. RECEIVING AND INSPECTION ..........................................................................................5

3. USER INTERFACE INFORMATION (PRE-OPERATION TESTING)..................................5

3.1.LED Indicators................................................................................................................5

3.2.Pressure Sensor ............................................................................................................6

4. OPERATION ........................................................................................................................6

4.1.Battery Installation and Removal ...................................................................................6

4.2.Die Assembly Installation and Removal.........................................................................6

4.3.Crimping.........................................................................................................................7

5. PREVENTIVE MAINTENANCE ...........................................................................................8

5.1.Daily Maintenance..........................................................................................................8

5.2.Yearly Maintenance .......................................................................................................8

5.3.Lubrication......................................................................................................................8

6. TROUBLESHOOTING .........................................................................................................8

6.1.Prior to Beginning Troubleshooting Procedures, Verify Battery is Operational..............8

6.2.Refer to Figure 5 for Problems, Probable Cause(s), and Solution.................................9

7. REPLACEMENT AND REPAIR ...........................................................................................9

8. DECOMMISSIONING...........................................................................................................9

9. RESTRICTION ON HAZARDOUS SUBSTANCES (RoHS) INFORMATION......................9

10. REVISION SUMMARY .........................................................................................................9

Standard Die Envelope (SDE) Lithium-

Ion Battery-Powered Crimping Tool

Kits; PN 2217480-[ ]

ORIGINAL INSTRUCTIONS

409-32031

Rev D

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SAFETY PRECAUTIONS —READ THIS FIRST!

IMPORTANT SAFETY INFORMATION

NOTE

Keep all decals clean and legible, and replace them

when necessary.

DANGER

ELECTRIC SHOCK HAZARD

This tool is not insulated. When using this unit near

energized electrical lines, use proper personal protective

equipment.

Failure to observe this warning could result in severe

injury or death.

DANGER

SKIN INJECTION HAZARD

Do not use hands to check for oil leaks. Highly

pressurized oil will puncture the skin causing serious

injury, gangrene, or death. If injured, seek medical help

immediately to remove the oil.

DANGER

FIRE HAZARD

Do not use solvents or flammable liquids to clean the

crimping tool. Solvents or flammable liquids could ignite

and cause serious injury or property damage.

Failure to heed these warnings could result in severe

injury from harmful fumes or burns from flying debris.

DANGER

FIRE HAZARD

Do not dispose of batteries in a fire. They will vent

fumes and will explode. Instead, dispose of batteries in

an environmentally responsible manner or send the

battery back to TE.

DANGER

Inspect the tool and jaws/dies before each use. Replace

any worn or damaged parts. A damaged or improperly

assembled tool can break and strike nearby personnel.

Failure to observe this warning could result in severe

injury or death.

CAUTION

—Do not place the tool in a vise. The crimping tool is

designed for hand-held operation.

—Protect the crimping tool from rain and moisture.

Water will damage the crimping tool and battery.

Failure to observe these precautions may result in injury

or property damage.

CAUTION

—Do not allow anything to contact the battery

terminals.

—Do not immerse the batteries in liquid. Liquid may

create a short circuit and damage the battery. If the

batteries are immersed, contact your service center for

proper handling.

—Do not place the battery into a pocket, tool pouch, or

tool box with conductive objects. Conductive objects

may create a short circuit and damage the battery.

—Do not place a battery on moist ground or grass.

Moisture may create a short circuit and damage the

battery.

Failure to observe these precautions may result in injury

or property damage.

CAUTION

—Do not store the battery at more than 60°C [140°F].

Damage to the battery can result.

—Do not use another manufacturer’s charger.

—Do not attempt to open the battery. It contains no

user-serviceable parts.

Failure to observe these precautions may result in injury

or property damage.

CAUTION

—Do not perform any service or maintenance other

than as described in this manual. Injury or damage to

the tool may result.

Failure to observe these precautions may result in injury

or property damage.

409-32031

Rev D

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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!

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 approved eye protection while operating

equipment.

Always wear appropriate ear protection while using

equipment.

Moving parts can crush and cut. Always keep guard(s)

in place during normal operation.

Electrical shock hazard.

Always turn off the main power switch and disconnect

the electrical cord from the power source when

performing repair or maintenance on the equipment.

Never insert hands into installed equipment.

Never wear loose clothing or jewelry that may catch in

moving parts of the equipment.

Never alter, modify, or misuse the equipment.

Do not operate equipment if the guards are removed.

Read and understand this entire document before

using equipment.

SUPPORT CENTER

CALL TOLL FREE 1-800-522-6752 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

The Support 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 SUPPORT CENTER

When calling the Support 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 Support Center, be ready with the following information:

Customer Name

Product part number (and serial number

if applicable)

Customer Address

Urgency of request

Person to contact (name, title,

telephone number, and extension)

Nature of problem

Person Calling

Description of inoperative component(s)

Equipment number (and serial number

if applicable)

10.

Additional information/comments that

may be helpful

409-32031

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Length

336.5 mm [13.25 in.]

Width

72.9 mm [2.87 in.]

Depth

114 mm [4.5 in.]

Mass/Weight (with Battery)

1.88 kg [4.2 lbs]

Sound Level

70 dBA at 1 Meter

Vibration

< 2.5 m/s2

Hydraulic Oil

Shell Tellus T15 or RIVOLTA S.B.H. 11

Maximum Crimping Force

15.6 kN [1.75 tons]

Average Crimping Time

2-4 seconds

Average Crimps per Charge

85-170 (Approx.)

Charging Voltage

18 V

Charging Time

15 Min. –1.3 AH/22 Min. –3.0 AH

Figure 1

INTRODUCTION

SDE lithium-ion battery-powered crimping tool kits 2217480-[ ] each consist of a battery crimping tool (with an

SDE crimping head installed), as well as two rechargeable battery cartridges used to power the tool. See

Figure 1.

Each kit has a battery charger. The battery charger part number, its voltage, and the kit region of use are listed

in Figure 2. The battery-powered crimping tool may or may not have a release switch to retract the ram.

When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.

DANGER

Denotes an imminent hazard that may result in moderate or severe injury.

CAUTION

Denotes a condition that may result in product or equipment damage.

NOTE

Highlights special or important information.

NOTE

Dimensions in this customer manual are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.

Crimping Tool Kit with Battery Cartridge Installed

Battery Lock

Battery Cartridge

2217332-1

Release Switch

(Kits 2217480-1

and -2 Only)

Light-Emitting Diode

(LED) Indicator Light

Trigger

Stationary

Jaw

SDE Crimping Head

Movable

Jaw

Shell and RIVOLTA are trademarks of their respective owners.

409-32031

Rev D

5 of 9

CRIMPING TOOL KIT

REGION OF USE

BATTERY CHARGER

BATTERY CHARGER VOLTAGE

RAM RETRACT SWITCH

2217480-1

North America

2217331-1

110 V

Yes

2217480-2

Europe

2217331-2

220 V

2217480-3

North America

2217331-1

110 V

Figure 2

Each kit is designed to accept interchangeable die assemblies used in PRO-CRIMPER* hand tools, which

crimp various types of product.

NOTE

This crimp tool accepts TE shoulder mounted die sets. Tool does not accept pin mounted die sets.

RECEIVING AND INSPECTION

Each kit 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 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 kit for the benefit of operation and

maintenance personnel.

The crimping tool should be inspected at regularly scheduled intervals, depending on care, degree of operator

skill, the type and size of the product to be crimped, and environmental conditions. At a minimum, the tool

should be inspected after every 40 hours of use.

USER INTERFACE INFORMATION (PRE-OPERATION TESTING)

LED Indicators

White LED Work Light

This LED automatically turns on when the trigger is pulled. The indicator remains lit for ten seconds after

the trigger is released.

Red LED Indicator

The tool is equipped with a special circuit board incorporating several important features. These features

inform the user of the current status of the tool. The red LED will signal in the cases given in Figure 3.

WHAT HAPPENS

WHAT IT MEANS

Red LED flashes for two seconds

The battery has been inserted in the tool

Red LED is lit constantly for 20 seconds at the end of the cycle

Battery charge is below 17 volts at the beginning of the cycle

Tool will not start. Red LED light remains lit for 20 seconds after trigger

is released

Battery charge is below 16 volts at the beginning of the cycle

Tool will stop. Red LED light remains lit for 20 seconds after the trigger

is released

Battery voltage drops below 13 volts during the cycle

Tool will stop. The LED will flash for 20 seconds after the trigger is

released

Motor current exceeds 20 A during the cycle

Circuit has become hot

Figure 3

409-32031

Rev D

6 of 9

Pressure Sensor

The tool is equipped with a pressure sensor that alerts the user of an incomplete crimp.

If the tool is manually retracted before completion of a crimp, the red LED will flash for two seconds

and an audible alarm will sound for two seconds.

If the tool is unable to reach the required crimp force, the red LED will flash for two seconds and an

audible alarm will sound until after the trigger is released.

NOTE

The tool has an on-board memory of previous crimp cycles and the cycle count. This information can be accessed and

downloaded onto a computer using USB Adapter Module 2217896-1.

OPERATION

Battery Installation and Removal

NOTE

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 crimping tool until it can go no further. There will be

an audible “click” from 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

crimping 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.

Die Assembly Installation and Removal

DANGER

To avoid personal injury, be sure to exercise extreme caution when handling the crimping tool. Remove the battery before

installing or removing the die assembly.

Each kit is supplied with an SDE crimping head installed on the battery-powered crimping tool. The only

installation required is the die assembly.

CAUTION

Do not operate the tool without the SDE crimping head installed. Damage to the ram or seals can result.

CAUTION

Do not operate the tool without the die assembly installed. Damage to the crimping head can result.

The following instructions are specific to the use of TE SDE die assemblies. Make sure to use only TE SDE die

assemblies.

Installation

1. Remove the battery from the crimping tool.

2. Remove the two die retaining screws from the crimping head.

3. Slide the upper die into the stationary jaw of the crimping head. Orient the upper die so that the

indenters face inward, with the largest indenter entering first, and the screw holes align. See Figure 4.

4. Insert the upper die retaining screw into the screw hole of the stationary jaw and through the screw

hole of the upper die. Tighten the screw just enough to hold the die in place. Do NOT tighten the

screw completely at this time.

Greenlee is a trademark.

409-32031

Rev D

7 of 9

5. Slide the lower die into the movable jaw of the crimping head. Orient the lower die so that the anvils

face inward, with the largest anvil entering first, and the screw holes align. See Figure 4.

6. Insert the lower die retaining screw into the screw hole of the movable jaw and through the screw hole

of the lower die. Tighten the screw just enough to hold the die in place. Do NOT tighten the screw

completely at this time.

7. Re-install the battery, then pulse the trigger to slowly close dies, making sure the crimping chambers

are properly aligned.

8. When the crimping chambers are aligned, tighten the die retaining screws.

Figure 4

Removal

1. Remove the battery from the crimping tool.

2. Remove the die retaining screws, then slide the dies out of the jaws of the crimping head.

Crimping

DANGER

To avoid personal injury, keep fingers clear of the crimping area.

1. Position the product to be crimped in the appropriate crimping chamber.

2. Depress the trigger to advance the ram. This closes the jaws to hold the product to be crimped in

place. Do not deform the wire barrel.

3. Insert a stripped wire in the wire barrel of the product to be crimped; making sure that the wire

insulation does not enter the wire barrel.

CAUTION

Do not use wires with nicked or missing conductor strands.

Stationary Jaw of

Crimping Head

Movable Jaw of

Crimping Head

Lower Die

Upper Die

Retaining Screw

Lower Die

Retaining Screw

Largest Anvil

Largest Indenter

409-32031

Rev D

8 of 9

4. Hold the wire in position, then depress and hold the trigger to complete the crimp. The crimping tool

will return automatically to the first position of its cycle when the crimp is complete.

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 -1 and -2 have a release switch.

CAUTION

This tool is not designed for continuous operation. After 100 cycles, allow the crimping tool to cool for 15 minutes.

CAUTION

Do not re-terminate the crimped product.

PREVENTIVE MAINTENANCE

Daily Maintenance

Perform the following maintenance daily:

1. Inspect the crimping head jaws and 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 from the crimping head, particularly in

areas where the crimping head is installed and the product is crimped. Wipe the entire tool frequently

with a clean, lint-free cloth.

Yearly Maintenance

Once per year or every 10,000 cycles (whichever comes first), the crimping tool should be returned to TE for

inspection.

Lubrication

Lubricate all pins, pivot points, and bearing surfaces with a high-quality grease. TE recommends the use of

Molykote paste, which is a commercially available lubricant.

Lubricate the crimping head in accordance with the following schedule:

Crimping head used in daily production: lubricated daily

Crimping head used occasionally in daily production: lubricate weekly

Crimping head used weekly: lubricate monthly

TROUBLESHOOTING

Prior to Beginning Troubleshooting Procedures, Verify Battery is Operational

1. Be sure that the battery is charged. Re-check 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 electrical contacts on the battery

and crimping tool.

3. Re-install the battery, and check the crimping tool again.

Molykote is a trademark.

409-32031

Rev D

9 of 9

Refer to Figure 5 for Problems, Probable Cause(s), and Solution

PROBLEM

PROBABLE CAUSE

SOLUTION

Tool is inoperative

Dirt, contaminants, etc., in ram area of tool

Return tool to TE for evaluation

Tool battery contacts damaged

Reform the contacts

Tool components are worn or damaged

Return tool to TE for evaluation

Jaws stop

during operation

Oil level is low

Return tool to TE for evaluation

Air in the hydraulic system

Pull trigger and hold retract button

simultaneously. Hold for approximately 10 seconds

Tool loses oil

Damaged internal seal

Return tool to TE for evaluation

Figure 5

REPLACEMENT AND REPAIR

DANGER

To avoid personal injury, ALWAYS remove the battery cartridge from the tool BEFORE performing any maintenance on the

crimping tool.

Kit replacement parts are identified in Figure 6. Order replacement parts through or return parts to your TE

representative, or call 1-800-526-5142, or send a facsimile of your purchase order to 717-986-7605. Or write to:

CUSTOMER SERVICE (038-035)

TE CONNECTIVITY CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

PART NUMBER

DESCRIPTION

2217332-1

Battery

2217331-1

Charger, 120 V, North America

2217331-2

Charger, 220 V, Europe

Figure 6

DECOMMISSIONING

In compliance with the regulations in force in the country where the tool is used, the user must make sure that

waste produced during operation is disposed of correctly. Disposal of lubricants and parts removed must be

carried out in compliance with the standards in force in the country where the tool is used.

RESTRICTION ON HAZARDOUS SUBSTANCES (RoHS) INFORMATION

Information on the presence and location of any substances subject to RoHS can be found at

http://www.te.com/customersupport/rohssupportcenter/

1. Click “Check Product Compliance and Get Statements of Compliance (SoC)”

2. Then click “Check Product Compliance Search Tool”

REVISION SUMMARY

Updated to current TE format, logo, and enterprise name

Added NOTE at end of Section 1

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