3. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A2 of 16
TECHNICAL ASSISTANCE CENTER
CALL TOLL FREE 1–800–722–1111
(CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number and extension)
4. Person calling
5. Machine or tool 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)
AMP Incorporated offers the Technical Assistance Center as a means of providing technical
assistance when required.
When contacting AMP Incorporated by telephone regarding service to a tool, 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
corrected in this manner.
When calling the Technical Assistance Center, be ready with the following information:
10. Additional information/comments that may be helpful
SAFETY PRECAUTIONS PREVENT INJURY
Safeguards are designed into AMP tools to protect operating personnel from most hazards during
normal tool operation. However, as with most tooling, certain precautions must be taken by the
operator and repairman to avoid personal injury or damage to the tool. Carefully observe the following safety
precautions, and those throughout the text, before and during operation of the tool.
Do not exceed maximum hydraulic line pressure or tool damage may occur.
Never insert hands into any part of a hydraulic–powered tool without first shutting off the system pressure in
the line at the pump control panel or pendant. This will prevent injury in the event that switches or other con-
trols are accidently activated. Never hold crimping dies of tool against hand or body when actuating tool. Tool
crimping head must be clear of all objects, or properly positioned on terminal post, when tool is actuated.
INFORMATION REQUIRED WHEN CONTACTING
4. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A 3 of 16
Hydraulic Unit 122271–2
Battery Pack 217981–1
Battery Charger 217982–1
This customer manual covers AMP Battery Operated Hydraulic Unit Assembly 122271–1, the Battery
Operated Hydraulic Unit 122271–2, and accessories (see Figure 1). The unit, which combines the convenience
of a hand tool with the power of a larger machine, is used primarily for the application of AMP terminals and
splices on larger wire sizes 8 AWG through 1500 MCM (see Figure 9).
The customer manual provides operating and maintenance procedures, as well as general information, for the
portable AMP Battery Operated Hydraulic Unit Assembly 122271–1. The customer is responsible for
maintenance of the unit. Maintenance procedures include adjustments, operating procedures, minor repairs,
and replacement of damaged or broken parts, battery recycling, as described in this manual.
For major repairs or production difficulties with the crimping head or pump unit, contact your AMP
representative; see Section 12, REPLACEMENT AND REPAIR.
The following instructions should be read carefully before operating the pump unit for the first time. The
performance of the unit will depend largely upon information contained in this manual and operator training and
skill. See Figure 9, which lists the crimping heads, instruction documentation, and products which may be
applied by this unit and the AMP Crimping Heads. Specifications for the AMP Battery Operated Hydraulic Unit
are listed in Figure 2.
5. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A4 of 16
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
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.
Reasons for reissue are provided in Section 14, REVISION SUMMARY.
All measurements on this document are in metric units [with U.S. customary units in brackets].
1.1. Receiving Instructions
Visually inspect all components for shipping damage. If any shipping damage is found, notify carrier at once.
Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or replacement costs
resulting from damage in shipment.
HYDRAULIC UNIT SPECIFICATIONS
Flow at 0 kPa [0 psi] 262 ml/minute [16 in3/minute]
Flow at 56539 kPa [8200 psi] 164 ml/minute [10 in3/minute]
Usable Oil Capacity 662 ml [38 in3]
Voltage 24 Vdc
Weight 8.4 kg [18.5 lbs]
LED Status Flashing Low Battery
Steady On Fault
BATTERY CHARGER SPECIFICATIONS
Voltage 100, 120, 220, 240 Vac
Frequency of Operation 50/60 Hz
Temperature Range 0_ – 50_ C [32_ – 155_F]
2.1. Battery Charger
The battery charger fully charges the battery pack in approximately one hour. Because the charger monitors
the charge on the battery, the battery can be removed from the charger at any time and replaced without
starting the charging cycle from the beginning. When recharged in the battery charger, the battery will not
exhibit a residual “memory effect,” and therefore does not require full discharging before recharging. Indicator
lights on the front panel show the status of the battery: READY, CHARGING, OVERHEAT, or DEFECTIVE. If
the battery is overheating, the charger shuts off, resuming the charging cycle once the battery has cooled
down. If the battery is defective, the charger shuts off.
Voltages are written on the surfaces of the fuse holder and, when located in the charging unit, can be seen through a
window on the charging unit. To select the appropriate voltage, remove the fuse holder and turn it until the desired
voltage faces the window of the charging unit.
6. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A 5 of 16
The battery pack (217981–1) is a 24 Vdc, 1.7 ampere/hour, rechargeable Nickel–Cadmium battery, designed
specifically for use with the Battery Operated Hydraulic Unit.
This battery pack contains Nickel–Cadmium, a hazardous material. Do not puncture, disassemble, mutilate, or
incinerate battery pack or cells.
To protect the life of the battery, use the battery pack only with the Battery Operated Unit 122271–1. Use only an
approved battery charger to protect the battery from overcharging.
2.3. Battery Operated Hydraulic Unit
The Battery Operated Hydraulic Unit is capable of producing up to 56539 kPa [8200 psi] of hydraulic pressure.
This is a light–weight, highly portable power source for single–acting tools that crimp terminals and splices. The
unit comes with a shoulder strap hand control pendant, charger, and a rechargeable Nickel–Cadmium battery
pack. Battery packs and chargers may also be ordered separately.
3. SAFETY INFORMATION
To avoid personal injury or property damage during system operation, read and follow all DANGER, CAUTION,
and NOTE statements included with or attached to each product. Please read the following informational items:
AMP CANNOT be responsible for damage or injury resulting from unsafe use of product, lack of maintenance, or
incorrect product and system application.
Contact AMP when in doubt as to application and safety precautions. See bottom of page 1.
To avoid personal injury, always wear proper personal protective gear when operating hydraulic equipment.
Make sure that all system components are protected from external sources of damage, such as excessive heat, flame,
moving machine parts, sharp edges, and corrosive chemicals.
Carry the unit by the handle or the strap. Carrying or dragging the unit by the hose can damage the hose and/or the
4.1. Battery Pack Installation
Slide the 217981–1 battery pack (A) into the pump battery compartment (B) until it latches into place. Figure 3
shows the proper installation of the battery pack.
The battery pack can be inserted only in the proper direction. Do not force the battery into the compartment.
4.2. Battery Pack Removal
To remove the battery pack, press down on the battery release latch (C) (see Figure 3) and the battery will
eject far enough to grasp and pull out.
Remove the battery pack from the unit when the unit is not in use. Storing the battery pack in the unit will cause
the battery pack to discharge rapidly. To protect the life of the battery pack, store it in the charger.
7. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A6 of 16
4.3. Hydraulic Connections (Figure 4)
Proceed as follows:
1. Connect a hose from the unit to the tool.
2. Hand–tighten quick–coupler (D) fully to ensure that all connections are tight and leak–free.
4.4. Filling the Reservoir (Figure 4)
Place unit on level surface. Unscrew the vent/fill cap (E) to expose the reservoir fill port. Add only high quality
hydraulic oil HF–101z or equivalent (see Figure 10). The reservoir is full when the oil level reaches the lip (F)
in the neck of the fill port.
Add oil only when the tool is fully retracted, or the system will contain more oil than the reservoir can hold, causing oil
to leak from vent/fill cap.
5.1. Oil Level
Check the oil level (see Figure 4) before operating the pump. If oil level is low, add oil until oil level reaches the
lip (F) in the neck of the fill port. Use only high quality hydraulic oil HF–101 or equivalent.
Venting is provided automatically through the vent/fill cap, which also protects against reservoir
z ENERPAC, a Unit of APPLIED POWER Inc.
8. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A 7 of 16
5.3. Indicator Light
Figure 5 shows the position of the indicator light (G). The light informs the operator when the battery is
depleted and when the motor has failed to operate.
When the battery needs recharging, the indicator light flashes, and will continue to flash until the battery has
If the motor does not operate, the indicator fault light will go on and remain on as long as the PRESSURE
button remains pressed. See Section 11, TROUBLESHOOTING, if the motor fails to operate.
5.4. With Dump and Hold Valve on Unit (Figure 5)
1. To advance the tool, press the PRESSURE button (1).
UNIT CONTROL PANEL
9. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A8 of 16
2. Release the PRESSURE button and the unit will hold the pressure.
3. To release system pressure and retract the tool, press the RELEASE button, (3), and hold until dies
have cleared the terminal to remove.
5.5. With Hand Control Pendant (Figure 6)
Figure 6 shows the operating positions of the pendant buttons. The pendant duplicates the operation of the
button(s) located on the unit control panel.
The function switches located on the unit control panel and the hand control pendant are both operable at the same
The indicator light (H) will glow when desired pressure has been reached.
Pressing the pendant PRESSURE button (1) activates the motor and advances the tool. Release the
PRESSURE button and the unit will hold pressure. Pressing the pendant RELEASE button (2) releases system
pressure and retracts the tool.
6.1. Battery Charging
For indoor use only. Keep the battery charger and adaptor away from direct sunlight, moisture, and extreme
The battery charger is for use with rechargeable Nickel–Cadmium batteries only.
The battery charger lights indicate the following:
Yellow––CHARGING Green––READY Orange––OVERHEAT Red––DEFECTIVE
Charge the battery by plugging in the charger and sliding the battery into the battery holder. The yellow light
flashes to indicate that the battery is charging.
When the green READY light goes on, the battery is fully charged.
If the orange OVERHEAT light goes on, do nothing. The charger automatically shuts off until the battery has
cooled, and then resumes the charging cycle.
10. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A 9 of 16
If the red DEFECTIVE light goes on, remove and re–insert the battery pack several times to ensure that the
battery is beyond recovery. If the yellow CHARGING light goes on, the battery may recover. If, through several
charge and use cycles, the use period increases dramatically, the battery is functioning properly. If the use
period does not increase dramatically, the battery is defective and should be disposed of properly. See Section
13, BATTERY RECYCLING.
The battery will not overcharge if left in the charger indefinitely. Once the battery is fully charged, the charger enters
the maintenance mode, monitoring the battery and keeping it fully charged. During the maintenance mode the yellow
light will flash periodically as the charge “tops off” the charge on the battery. See Figure 7).
6.2. Battery Care (Figure 7)
Store the battery in the charger to keep it fully charged and ready for use. Shelf storage will result in slow
discharge of the battery. Store the battery and charger in a cool, dry environment. See NOTE above.
Storing the battery in the pump will cause the battery to discharge rapidly. If the battery is not removed from the pump
when the low battery indicator light turns on, the battery life will be shortened.
The battery pack is equipped with a fuse. If the fuse is blown, it must be replaced with a 30–ampere
automotive “mini” fuse (Littlefuse Part Number 297030).
DO NOT DISCARD! The battery pack contains hazardous material. Dispose of the battery pack in accordance with
local recycling regulations. For more information on recycling the battery pack, see Section 13, BATTERY
6.3. Changing the Oil
Change the oil in the unit once a year.
1. To drain oil, attach an open–ended hose to the quick–coupler (see Figure 5); depress PRESSURE
button, actuating the motor and drain oil into a suitable container.
11. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A10 of 16
2. Unscrew and remove the vent/fill cap.
3. Add new hydraulic oil until oil level reaches the lip in the neck of the fill port.
4. Dispose of used oil properly.
7.1. Crimping Heads
The Battery Operated Hydraulic Unit uses interchangeable crimping heads. Each crimping head uses
interchangeable crimping dies (with the exception of crimping head 69069, which has integral dies designed for
that particular head). The products to be crimped in each head are listed in the instructions accompanying the
7.2. Crimping Dies
Each crimping head, except as noted in the preceding paragraph, uses interchangeable crimping dies designed
for that particular head. The instructions packaged with the dies give complete information.
7.3. Latch Pin Kits
Latch pin kits are available as accessories for the crimping heads as listed and shown in Figure 8.
7.4. Hose Assemblies
Hoses are sold separately as accessories and are available in different lengths; lengths and part numbers are
listed in Figure 8.
LATCH PART NUMBER HOSE ASSEMBLY NUMBER
KIT NUMBER PART NUMBER LENGTH MM [IN.]
69051 69709 314990–1 .61 
69065 69709–2 314990–2 .91 
69066 69709–3 314990–3 2.13 
69067 69709–4 314990–4 14.57 
12. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A 11 of 16
CRIMPING HEADS INSTRUCTION
Radiation Resistant, and Pre–Insulated
AMPOWER Terminals and TERMINYL*,
and COPALUM* Terminals and Splices
Terminals and Splices
Radiation Resistant, Pre–Insulated
AMPOWER and Pre–Insulated Nylon
Heavy Duty Terminals and TERMINYL,
and COPALUM Sealed Terminals and
SOLISTRAND Terminals and
Terminals, Flag Terminals
SOLISTRAND Terminals and Splices
AMPOWER, COPALUM and
SOLISTRAND Terminals and
AMPOWER Quick Disconnect
Terminals and COPALUM Insulation
Piercing Terminals and Splices, Open
Post–Insulated STRATO–THERM and
COPALUM Terminals and Splices
COPALUM and Post–Insulated, and
Terminals and Splices, AMPOWER
Quick Disconnect Terminals,
SOLISTRAND Flag Terminals,
COPALUM Insulated Piercing
Terminals and Splices and
TERMI–FOIL Terminals, Open Barrel
Terminals, Stamped and Cast Battery
TERMINYL, Radiation Resistant,
Pre–Insulated AMPOWER, Pre–Insulated
Nylon Terminals, and Sealed COPALUM
Terminals and Splices
SIZES 8 THRU 2
THRU 600 MCM
THRU 4/0 AWG
THRU 4/0 AWG
THRU 4/0 AWG
SIZE 1250 MCM
THRU 1500 MCM
THRU 1/0 AWG
THRU 1000 MCM
SIZES 12–10 AWG
THRU 350 MCM
THRU 4/0 AWG
68073–2 408–2449 AMPOWER* Terminals and Splices
THRU 2 AWG
13. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A12 of 16
8. RECEIVING INSPECTION
1. Remove unit from shipping carton.
The unit is a precision–built pump. ANY foreign particles entering the hydraulic fluid will damage polished surfaces,
resulting in a loss in performance. It is important that the area around the reservoir filler cap and all threaded fittings be
cleaned before filling and assembly.
2. Thoroughly clean coupling areas of the hose and crimping head.
3. Remove protective dust caps from couplers, then assemble:
a. hydraulic hose quick–coupler to pump unit;
b. crimping head to hydraulic hose;
c. install crimping dies in crimping head (see instruction sheet packaged with dies for installation
Avoid personal injury: remove battery pack before changing dies.
8.2. Removal of Crimping Head
Unmating the quick–couplers facilitates removal of the crimping head; hold RELEASE button to ensure all
pressure is removed from hose; then, unscrew collar on coupler.
9. OPERATING PROCEDURE
1. Advance ram partially by depressing PRESSURE button momentarily.
2. With dies partially closed, place terminal or splice in dies.
3. Once again, depress PRESSURE button to advance dies just enough to retain terminal or splice. The
dies will maintain a “hold” position long enough to allow the operator to insert wire(s) into a terminal or
splice before completing the crimping cycling.
If the PRESSURE button is depressed for too long, the dies will advance fully and crimp the wire barrel of the terminal
or splice before wire(s) can be inserted.
If it is necessary to retract dies without completing crimp cycle, depress RELEASE button.
4. Insert stripped wire to proper insertion depth or wire stop in terminal or splice.
When crimping large wire splices: if possible, insert stripped wire into both ends of splice so that they butt against wire
stops in middle of splice. If first crimp is made without conductors in both ends, the second conductor may be more
difficult to insert due to partial deformation of the splice. Rectangular conductors should be inserted so that crimping
pressure is applied to the flat side of the conductors.
5. Depress PRESSURE button until unit completes cycle and motor stops.
6. Depress RELEASE button to retract dies and then remove crimped terminal or splice.
10. PREVENTIVE MAINTENANCE
It is important that a preventive maintenance program be established and that maintenance be performed at
regular intervals to ensure efficient, dependable performance of the unit. The preventive maintenance program
includes cleaning, visual inspection, checking release/kickoff pressure, and tightening of all external screws
and electrical connectors.
14. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A 13 of 16
Clean breather hole in hydraulic oil vent/fill cap frequently, including the area surrounding the vent/fill cap.
Perform an overall visual inspection of the entire unit at least once a month.
1. Check hydraulic oil level.
2. Inspect hoses for damage.
3. Check hydraulic release pressure.
10.2. Hydraulic Oil Specifications
If additional oil is required, it is essential that the proper grade of high–quality oil be used. Specifications and
examples of high–grade hydraulic oil for use in the unit are shown in Figure 10.
SPECIFICATIONS for HF–101 or EQUIVALENT
Viscosity Index 100/minute.
Viscosity at 99_C [210_F] 42/45 S.U.S. (Saybolt Universal Seconds)
Viscosity at 38_C [100_F] 150/165 S.U.S. (Saybolt Universal Seconds)
Viscosity at –17.8_C [0_F] Less Than 12,000 S.U.S.
API Gravity 31.0/33.0
Flash Point, C.O.C. (Cleveland Open Cup) 204_C [400_F]
Pour Point –32_C [–25_F]
Aniline Point 99 to 104_C [210 to 220_F]
Paraffinic Base Color Blue
15. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A14 of 16
The following information is intended as an aid in determining if a problem exists. Do NOT disassemble the
pump. For repair service, return the unit to AMP Incorporated; see Section 12, REPLACEMENT AND REPAIR.
PROBLEM POSSIBLE CAUSE SOLUTION
Tool does not advance,
advances slowly or
Oil level in pump reservoir is low. Add oil per Paragraph 4.4.
advances slowly, or
advances unevenly. Release valve open. Close the release valve.
Loose hydraulic coupler. Check that all couplers are fully tightened.
Air trapped in system. Remove air by holding the unit higher than the tool and cycling it
several times without building pressure.
Cylinder plunger binding. Check that all connections are tight and leak–free.
Tool advances, but does not
Leaking connection. Check that all connections are tight and leak–free.
Leaking seals. Locate leak(s) and have equipment serviced by a qualified hydraulic
Internal leakage in pump. Have unit serviced by a qualified hydraulic technician.
Tool does not retract,
retracts part way or retracts
Release valve closed. Open release valve.
retracts part way, or retracts
more slowly than normal. Pump reservoir is over filled. Drain oil level to lip in reservoir neck .
Loose hydraulic coupler. Check that all couplers are fully tightened.
Air trapped in system. Remove air by holding the unit higher than the tool and cycling
several times without building pressure.
Hose ID too small. Use a hydraulic hose with a larger diameter.
Crimp head retraction spring
broken or other cylinder damage.
Return crimp head to AMP, see Section 12, REPLACEMENT AND
Motor fails to operate,
Red light “on ”
Internal thermal switch is open. Wait approximately 20 minutes for the motor to cool.
Red light “on.”
Break in the wiring. Have the unit serviced by a qualified hydraulic technician.
Failure of the motor relay. Have the unit serviced by a qualified hydraulic technician.
12. REPLACEMENT AND REPAIR
It may be necessary to return the unit to AMP Incorporated for repairs. Ship the unit (secured in an appropriate
shipping crate or container) to:
CUSTOMER REPAIR (01–12)
1523 NORTH 4TH STREET
HARRISBURG, PA 17102–1604
Include a written description of the problem and what efforts were made to correct it before shipping the unit to
AMP for repair.
Before electing to ship the unit to AMP for repair, it is advisable to contact the AMP Technical Assistance Center; see
bottom of page 1.
409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A 15 of 16
13. BATTERY RECYCLING
The battery pack contains Nickel–Cadmium, a hazardous material. The battery pack must be recycled.
Send used batteries to:
SANYO ENERGY (U.S.A.) CORPORATION
2001 SANYO AVENUE
SAN DIEGO, CA 92173
When shipping used batteries:
1. Store the battery for 90 days to be sure it is fully discharged.
NEVER short the terminals of the battery pack to discharge it.
2. Choose a box size with minimal empty spaces to reduce the possibility of contents shifting.
Do not fill spaces in the package with paper or flammable material.
3. Seal box with packing tape.
4. Use an approved carrier and label the box: “Used Nickel–Cadmium Battery(s) for Recycling.”
You MUST use a Bill of Lading and include all information requested in the Bill, or Sanyo Energy Corporation may
return the shipment to you at your expense. The sample Bill of Lading, shown in Figure 11, may be used or copied.
Bill of Lading
Date of Transfer:
Description of Contents: Waste Nickel Cadmium Battery(s) lbs.
SANYO Energy (U.S.A.) Corp.
2001 Sanyo Avenue
San Diego, CA 92173
17. 409–5869Battery Operated Hydraulic Unit Assembly 122271–1
Rev A16 of 16
14. REVISION SUMMARY
This manual was revised according to EC 015–3395–95.
S Battery charger voltage, frequency, and temperature range specifications were added to Figure 2.
S Note was added in Paragraph 2.1 describing voltage selection.
S Changed Hose Assembly Part Numbers in Figure 8
S Deleted TERMALUM, COPALUM Sealed, and Inhibitor Filled COPALUM from Figure 9.