Hydraulic Press Assembly Hydraulic Press Assembly Operation Manual Order No. 19286-1000 Description Operation Maintenance Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 1 of 30 Hydraulic Press Assembly Safety Warnings and Information Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Keep this manual available when using this tool. Replacement manuals are available for download at no charge at www.molex.com. SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. DANGER: DANGER Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. WARNING: WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events that could lead to personal injury. WARNING Always wear proper eye protection when Operating or servicing this equipment. Failure to wear eye protection could result in serious eye injury from flying debris. WARNING Never wear clothing or jewelery that is loose or That could potentially hang into the equipement and get caught. Failure to observe this warning could result in Severe Injury or death. WARNING Never operate, service, install, or adjust this machine without proper instruction and without first reading and understanding the instructions in this manual and all applicable tool and/or wire processing machine. manuals. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 WARNING Heavy Object To avoid muscle strain or back injury, use lifting aids and proper lifting techniques when removing or replacing. Failure to observe these precautions may result in injury or property damage. WARNING Never install or service this machine while connected to any electrical power source. Disconnect power by unplugging this tool from its power source. Failure to observe this warning could result In severe injury or death. WARNING Always wear proper ear protection when Operating or servicing this applicator. Failure to observe these precautions may result in Injury or property damage. UNCONTROLLED COPY Page 2 of 30 Hydraulic Press Assembly WARNING WARNING Do not use compressed air to clean this equipment. The forces created by compressed air can force debris into the tool. Never use this tool without guards or safety devices that are intended to prevent hands from remaining in the die space. Failure to observe this warning could result In severe injury or death. Failure to observe these precautions may result in injury or property damage. WARNING WARNING Hand/Foot Operated Maximum Capacity: 10,000 PSI Do not exceed the PSI hydraulic rating noted on the pump nameplate or tamper with the internal high-pressure relief valve. Before operating the hydraulic pump, all hose connections must be tightened with proper tools. Do not over-tighten. Connections need only be tightened securely and leak-free. Over-tightening may cause premature thread failure or may cause high-pressure fittings to split at pressures lower than their rated capacities Pump Before replenishing the oil level, retract the system to prevent overfilling the pump reservoir. An overfill may cause personal injury due to excess reservoir pressure created when cylinders are retracted. Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off the pump and shift the control valve twice to release all pressure. WARNING Never attempt to grasp a leaking hose under pressure with your hands. The force of escaping hydraulic fluid could cause serious injury. Air Hydraulic Do not subject the hose to potential hazard such as fire, Pump extreme heat or cold, sharp surfaces, or heavy impact. Do not allow the hose to kink, twist, curl, or bend so tightly that the oil flow within the hose is blocked or reduced. Periodically inspect the hose for wear because any of these conditions can damage the hose and possibly result in personal injury. Cylinder Do not exceed rated capacities of the cylinders. Excess pressure may result in personal injury. Do not set poorly balanced or off- center loads on a cylinder. The load may tip and cause personal injury. Do not use the hose to move attached equipment. Stress may damage hose and possibly cause personal injury. Hose material and coupler seals must be compatible with the hydraulic fluid used. Hoses must not encounter corrosive materials such as creosote-impregnated objects and some paints. Consult the manufacturer before painting a hose. Creating pressure beyond rated capacities may result in personal injury. WARNING Air Supply Shut off and disconnect the air supply when the pump is not in use or before breaking any connection in the system. Never paint the couplers. Hose deterioration due to corrosive materials may result in possible personal injury Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 3 of 30 Hydraulic Press Assembly WARNING MOLEX CANNOT BE RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM UNSAFE PRODUCT USE, LACK OF MAINTENANCE, OR INCORRECT PRODUCT AND SYSTEM APPLICATION. CAUTION Failure to observe these precautions may result in injury or property damage. CAUTION Never perform any service or maintenance other than as described in this manual. Never modify, alter or misuse the equipment Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling. Failure to observe this precaution may result in injury and property damage. Tooling Technical Assistance Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments. This support can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling Group. Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global). This assistance is limited to the operation and set-up of a customer's Molex Press Assembly. Questions with regard to Molex connector products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex personnel or Customer Service Representative. When calling for service on the tool a copy of the Tooling Manual and Specific Applicator Tooling Specification Sheet should be present and a person that is familiar with the applicator should be present. Be sure the following information is supplied: 1. 2. 3. 4. 5. 6. 7. 8. Customer name Customer address Person to contact such as (name, title, e-mail, and telephone number Press order number (Lease number also if applicable) Serial number (Lease number also if applicable) Molex Connector product order number Urgency of request Nature of problem Molex Application Tooling Group 2200 Wellington Court Lisle, IL 60532, USA Tel: +1 (630) 969-4550 Fax:+1 (630) 505-0049 Visit our Web site at http://www.molex.com Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 4 of 30 Hydraulic Press Assembly Table of Contents Contents Hydraulic Press Assembly ............................................................................................................................................. 1 Order No. 19286-1000................................................................................................................................................... 1 Safety Warnings and Information .................................................................................................................................. 2 Table of Contents .......................................................................................................................................................... 5 Section 1 ....................................................................................................................................................................... 6 General Description .................................................................................................................................................. 9 1.1 Description .................................................................................................................................................... 9 1.2 Features ........................................................................................................................................................ 9 1.3 Technical Specification .................................................................................................................................. 9 1.4 Delivery Check .............................................................................................................................................. 9 1.5 Tools.............................................................................................................................................................. 9 Section 2 ..................................................................................................................................................................... 10 Hydralic Head Crimper (19286-0117) .......................................................................................................................... 10 Principal Mechanical Parts of the 19286-0117 (PPHHLS) ...................................................................................... 11 2.1 Set-Up ......................................................................................................................................................... 12 2.2 Hydraulic Connections and Optional Bench Mounting................................................................................. 12 2.3. Installation of Tool Kits ................................................................................................................................ 13 2.4 Terminal Specifications and Crimping Operation......................................................................................... 14 Section 3 ..................................................................................................................................................................... 15 Terminal Locator (19286-0300) ............................................................................................................................... 15 3.1 Removing and Installing the Guards and the Terminal Locator Assembly................................................... 16 3.2 Operation..................................................................................................................................................... 16 3.3 Adjustments................................................................................................................................................. 18 3.4 Tool Change Over ....................................................................................................................................... 19 Section 4 ..................................................................................................................................................................... 20 Preventive Maintenance.......................................................................................................................................... 20 4.1 Lubrication ................................................................................................................................................... 21 4.2 Bleeding Air From The System .................................................................................................................... 21 4.3 Inspecting The Hydraulic Fluid Level ........................................................................................................... 21 4.4 Draining and Flushing the Reservoir ........................................................................................................... 21 4.5 Refilling The Reservoir ................................................................................................................................ 21 4.6 Venting the Reservoir .................................................................................................................................. 22 4.7 Priming the Pump Unit................................................................................................................................. 22 4.8 Periodic Cleaning ........................................................................................................................................ 22 4.9 Spare Parts ................................................................................................................................................. 23 4.10 Perishable Parts (Tool Kits) ......................................................................................................................... 23 4.11 Storage ........................................................................................................................................................ 23 Section 5 ..................................................................................................................................................................... 24 5.1 19286-1000 Main Parts List and Assembly Drawings ................................................................................. 25 5.1 19286-0051 Parts List and Assembly Drawing ............................................................................................ 26 5.2 19286-0117 Parts List and Assembly Drawing ............................................................................................ 27 5.3 19286-0300 Parts List and Assembly Drawing ............................................................................................ 28 5.4 Troubleshooting ........................................................................................................................................... 29 Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 5 of 30 Hydraulic Press Assembly Section 1 General Description 1 Description 2 Setup and Adjustments 3 Crimping Dies Go-No go 4 Preventive Maintenance 5 Parts List, Assembly Drawings and Troubleshooting Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 6 of 30 Hydraulic Press Assembly Section 1 General Description 1.1. Description 1.2. Features 1.3. Technical Specifications 1.4. Delivery Check 1.5. Tools Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 7 of 30 Hydraulic Press Assembly Principal Mechanical Parts of the 19286-1000 FILTER REGULATOR GAUGE AIR HOSE HYDRAULIC HOSE ASSEMBLY HYDRAULIC HEAD ASSEMBLY PUTT PUMP POWER UNIT C-FRAME STAND ASSEMBLY RESERVOIR UNIT VENTED CAP TERMINAL LOCATOR ASSEMBLY Figure 1-1 CRIMP DIES Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 8 of 30 Hydraulic Press Assembly General Description 1.4 1.1 Description Carefully remove the Molex Hydraulic Press Assembly from its shipping container and determine that the following items are included in the package. The Molex Hydraulic Press Assembly includes the basic Molex Hydraulic Head Crimper (Order No. 19286-0117) with added features to Crimp the Imperium Plus product line. Delivery Check The crimping Dies are not included with the 19286-1000 press assembly. Refer to the Section 2.4 for the application chart for die order numbers and description. Hydraulic Head Crimper 19286-0117 C-Frame Stand Assembly 19286-0051 Terminal Locator Assembly 19286-0300 Pump Assembly with hoses, filter, regulator, and gauge assembly (Includes vented cap for pump) 1.2 Features Operation Manual A fully adjustable terminal locator designed for the Imperium Product Line All guards and terminal locator can be reversed for right or left hand operation Crimping dies are easily and quickly interchanged to reduce production down time. Complete portable system that allows tool to be moved and stored easily. 1.3 Technical Specification 1.5 ATS-192861000 Tools The following tools are recommended for setup and adjustments to this tool. 1. 2. 3. 4. 5. Metric standard hex wrench set Inch standard hex wrench set Adjustable wrench Wire stripper / cutter Screw driver Pneumatic: Supply Pressure: 100 PSI (6.9 Bars) 125-PSI max. (8.6 Bars max.) Cycle Time: 15 seconds Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 9 of 30 Hydraulic Press Assembly Section 2 Hydralic Head Crimper (19286-0117) Set-Up and Operation 2.1. Setup 2.2. Connection and Bench Mounting 2.3. Installation of Tool Kits 2.4. Terminal Specifications and Crimping Operation Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 10 of 30 Hydraulic Press Assembly Principal Mechanical Parts of the 19286-0117 (PPHHLS) FILTER REGULATOR GAUGE AIR HOSE HYDRAULIC HOSE ASSEMBLY PUTT PUMP POWER UNIT HYDRAULIC HEAD ASSEMBLY RESERVOIR UNIT VENTED CAP REF C-FRAME STAND ASSEMBLY (NOT INCLUDED WITH THE 19286-0117 PRESS Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 Figure 2-1 UNCONTROLLED COPY Page 11 of 30 Hydraulic Press Assembly CAUTION: Always disconnect the air supply until the system is ready to operate. 2.1 Set-Up The principal mechanical parts of the 19286-1000 are illustrated in Figure 2-1 and Section 5 in this document. Air Supply Hook-Up WARNING: Seal all external pipe connections with a high quality, non-hardening pipe sealant. Teflon tape may also be used to seal hydraulic connections if only one layer of tape is used. 1. Select the 1/4 NPT threaded fittings that are compatible with your air supply. 2. Remove the red plastic thread protector from the putt pump on the air connection. Pull out and discard then attach the air fitting. 3. Next, install the fittings to the filter, regulator, and gauge unit. The air supply should be 20 CFM (550 L/M) and 100 PSI (6.9 Bars) to obtain the rated hydraulic output. Air pressure should be regulated to a maximum of 125 PSI (8.6 Bars). See Figure 2-2. 4. Before installing the hydraulic hose, unscrew the square nut on the putt pump outlet and discard. Attach the hose assembly to the hydraulic fluid outlet. HYDRAULIC HOSE QUICK DISCONNECT COUPLER FILTER, REGULATOR, AND GAUGE LUBRICATOR (OPTIONAL) FILTER CAP RED FOR SHIPPING AND BLACK (VENTED) FOR OPERATION HYDRAULIC HEAD ASSEMBLY AIR SUPPLY CUSTOMER SUPPLIED DUST CAP REF PUMP AIR HOSE Figure 2-2 2.2 Hydraulic Connections and Optional Bench Mounting 1. 2. 3. 4. Remove the dust cap from the cylinder on the crimp head. Connect the quick disconnect coupler onto the cylinder inlet on the crimp head. See figure 2-2. Replace the red filler cap on the pump reservoir with the black-vented cap that is supplied with the unit. To mount the hydraulic head assembly to the optional C-Frame stand, loosen the three thumbscrews in the stand. 5. Place the hydraulic head in the stand with the cylinder facing up. Tighten the thumbscrews; making sure the hydraulic head is securely positioned. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 12 of 30 Hydraulic Press Assembly Note: The safety guard panals will need to be removed before attempting to fasten the hydraulic to a work bench. See Section 3.1 Removing and Installing the Guards and the Terminal Locator Assembly for more information. 6. When using the optional C-Frame stand, be sure the C-Frame stand assembly is securely fastened to a clean, sturdy workbench or table in a well-lighted area. Fasten the stand with four #3/8-16 SHCSs, nuts, and washers of sufficient length for the tabletop. (Not supplied). See Figure 2-4. (Some stands may have two mounting holes instead of four.) C-FRAME STAND #3/8-16 SHCS (4) C-FRAME STAND HYDRAULIC HEAD #3/8 WASHER (8) THUMB SCREW (3) Figure 2-3 2.3. Installation of Tool Kits WORK BENCH Figure 2-4 #3/8-16 HEX NUT (4) CAUTION: Always disconnect the air supply until the system is ready to operate Before crimping, set the recommended air pressure gauge for the hydraulic pump (See Section 2.1) to obtain the proper crimp. #8-32 SET SCREW TOP TOOL HOLDER PUNCH (NEST) TOOL HOLDERS ANVIL (INDENTOR) Figure 2-5 #8-32 SETSCREW LOWER TOOL HOLDER HYDRAULIC HEAD 1. Connect the female coupler firmly with the male coupler of high-pressure rubber hose, which is attached to the hydraulic pump. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 13 of 30 Hydraulic Press Assembly 2. Select the proper set of dies for the terminal being crimped. The wire size is marked on each die. See Section 2.4. CAUTION: Be sure to use the correct pair of dies for the appropriate wire and terminal. 3. Loosen the #8-32 setscrew in the upper tool holder in the hydraulic head assembly. Place the punch (Nest) in the top tool holder and retighten the setscrew. See Figure 2.5. 4. Loosen the #8-32 set screw in the lower tool holder in the hydraulic head assembly. Then, place the anvil (Indentor) in the lower tool holder of the hydraulic head assembly and retighten the setscrew. CAUTION: A wrong combination of dies may cause critical damage to the tool. 2.4 Terminal Specifications and Crimping Operation SCOPE This tooling is designed to crimp Molex Imperium and Imperium Plus. Imperium and Imperium Plus Wire Size Wire Finish Bare Copper 1 AWG Pre-Tinned Post-Tinned Bare Copper 2/0 Pre-Tinned Post-Tinned Crimp Die Application Chart Wire Type Terminal Crimp Die Press Conductor Diameter.range (mm) Order No. Order No. Order No. 779 (strand)/30 171423-1401 19290-0100 (9.40 Max. Conductor Diameter) 817 (strand)/30 171423-1401 19290-0100 19286-1000 (9.40 Max. Conductor Diameter) 779 (strand)/30 171423-1401 19290-0100 (9.40 Max. Conductor Diameter) 1254 (strand)/30 171423-1201 19290-0350 (11.3 Max. Conductor Diameter) 1330 (strand)/30 171423-1001 19290-0300 19286-1000 (12.50-11.35mm Diameter) 1254 (strand)/30 171423-1001 19290-0300 (12.50-11.35mm Diameter) See the ATS Document for the proper Crimp Die. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 14 of 30 Hydraulic Press Assembly Section 3 Terminal Locator (19286-0300) 3.1 Installing Guards and Terminal Lcator Assemblies 3.2 Operation 3.3 Adjustments 3.4 Tool Change Over Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 15 of 30 Hydraulic Press Assembly 3.1 Removing and Installing the Guards and the Terminal Locator Assembly CAUTION: Always disconnect the air supply until the system is ready to operate. The safety guards and the terminal locator assembly are factory installed on the 19286-1000 Press. The clear safety guard panels will need to be temporarily removed for crimp die replacement or terminal locator replacement. 1. 2. 3. 4. Remove the (12) twelve M5 SHCS holding the front and side safety guards. Remove the safety guards. See Figure 3-1. When all set up and adjustments are made reinstall the safety guards. Tighten the M5 SHCS. REMOVE THIS SAFTEY GUARD PANEL BEFORE MOUNTING THE PRESS TO A WORK BENCH SIDE SAFTEY GUARD PANEL REMOVED M5 SHCS (4) FRONT SAFTEY GUARD PANEL REMOVED Figure 3-1 M5 SHCS (4) The Terminal Locator Assembly 192860300 is for the Imperium and Imperium Plus product line. This assembly ensures the correct location of the terminal during crimping. 3.2 Operation 1. Insert the properly stripped cable into the terminal barrel. 2. Position the terminal into the slot of the safety guard shown in figure 3-2 and above the the lower crimp tool (anvil) until it stops. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 16 of 30 Hydraulic Press Assembly LOWER TOOLING (ANVIL) TERMINAL STOP 192860306 (REF) POSITION TERMINAL THROUGH SAFETY GUARD SLOT TERMINAL SERIES 171562 (REF) TERMINAL LOACATOR ASSEMBLY Figure 3-2 SAFETY GUARD 3. The rim of the terminal should be against the stop of the terminal locator assembly. 4. For the correct terminal placement and the proper locator see Figure 3-3 and 3-4. 17.3mm-18.3mm UPPER TOOLING (PUNCH) RIM OF TERMINAL AGAINST STOP STOP RECEPTACLE No. 192860301 TERMINAL SERIES No. 171562 LOWER CRIMP TOOL (ANVIL) Figure 3-3 Note: During termination a slight movement of the locator stop may occur. This is normal the locator stop will return to the correct position once the terminal is removed from the press. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 17 of 30 Hydraulic Press Assembly UPPER TOOLING (PUNCH) 15.0mm-14.0mm RIM OF TERMINAL AGAINST STOP STOP PLUG No. 192860307 LOWER CRIMP TOOL (ANVIL) TERMINAL SERIES No. 171423 Figure 3-4 1. Depress the pedal on the putt pump to activate the tool. The crimping process is done in small increments gradually allowing the press to fully crimp the terminal into the wire. 2. After the terminal is fully crimp, depress the elevated portion of the pedal to release the pump. This will allow the tool to release. 3. Remove the crimp and inspect for proper crimp location. 3.3 Adjustments CAUTION: Always disconnect the air supply when before any adjustments or changing out tooling. The Terminal Location Adjustment must be adjusted, so that the crimp is located as shown on Figuure 3-3 and 3-4. ADJUSTING SCREWS LOCATOR STOP Note: It is not necessary to remove the safety guarding to make this adjustment. 1. Insert a 4.0mm socket style wrench thru the holes provided in the safety guards, and loosen the two locking screws. Do not remove them. See Figure 3-5. 2. Using the 4.0mm socket wrench, turn the adjusting screws to achieve the correct crimp location. 3. Turning the adjusting screws clockwise will increase the distance from the rim to the crimp. 4. Turning the screws counter-clockwise decreases this distance. 5. After adjustment are made, retighten the two locking screws. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 LOCKING SCREWS UNCONTROLLED COPY Figure 3-5 Page 18 of 30 Hydraulic Press Assembly 3.4 Tool Change Over CAUTION: Always disconnect the air supply when before any adjustments or changing out tooling. 5. Before changing out the tooling the safety guard panels must be removed. 6. Remove the (8) eight M5 SHCS holding the front and side safety guards. 7. Remove the safety guards. See Figure 3-6. SIDE SAFTEY GUARD PANEL REMOVED FRONT SAFTEY GUARD PANEL REMOVED M5 SHCS (4) M5 SHCS (4) Figure 3-6 8. 9. 10. 11. 12. 13. To change the locator stop remove the (2) two M5 x 18 long SHCS on the locking block. Remove the (2) springs in the frame stop. Lift out the locator stop and set aside. Install the new locator stop. Replace the (2) springs and the locking block. Install the (2) two M5 x 18 long SHCS on the locking block and tighten. See Figure 3-7. REMOVE LOCATOR STOP LOCKING BLOCK FRAME STOP M5 X 18 LONG SHCS (2) SPRING (2) Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 NEW LOCATOR STOP Figure 3-7 UNCONTROLLED COPY Page 19 of 30 Hydraulic Press Assembly Section 4 Preventive Maintenance 4.1 Lubrication 4.2 Bleeding Air From the System 4.3 Inspecting the Hydraulic Fluid Level 4.4 Draining and Flushing the Reservoir 4.5 Refilling the Reservoir 4.6 Venting the Reservoir 4.7 Priming the Pump Unit 4.8 Periodic Cleaning 4.9 Spare Parts 4.10 Perishable Parts 4.11 Storage Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 20 of 30 Hydraulic Press Assembly 4.1 Lubrication WARNING: Any repair or servicing, which requires dismantling the pump must be performed in a dirt-free environment by a qualified technician. CAUTION: Always disconnect air supply before all maintenance. If the pump is operated on a continuous duty cycle for extended periods, the manufacturer recommends an automatic airline oiler be installed in the air inlet as close to the pumping unit as possible. Set the unit to feed approximately 1 drop of oil per minute into the system. Use SAE No. 10 oil. 4.2 Bleeding Air From The System During the initial moments of activation or after prolonged use, a significant amount of air may accummulate within the hydraulic system. This entrapped air may cause the cylinder to respond slowly or behave in an unstable manner. To remove the air, run the system through several cycles (extending and retracting the ram) free of any load. The rams must be at a lower level than the pump to allow air to be released through the pump reservoir. 4.4 Draining and Flushing the Reservoir IMPORTANT: Wipe the pump exterior completely clean before attempting this procedure! 1. Loosen and remove the six screws that fasten the pump assembly to the reservoir. Remove the pump assembly from the reservoir. Do not damage the gasket, filter, or safety valve. 2. Clean the inside of the reservoir and refill with a suitable, non-flammable flushing oil. Rinse the filter clean. 3. Place the pump assembly back onto the reservoir and secure with two of the six screws. For best results, assemble the screws in opposite corners of the housing. 4. Run the unit for several minutes. Use the same method described in Section 3-7 (Priming the pump unit) 5. Drain and clean the reservoir once more. 6. Refill the reservoir with an approved, clean hydraulic oil and replace the pump assembly (with gasket) on the reservoir. Assemble the six machine screws and torque 25 to 30 in. lbs. IMPORTANT: Drain and clean the other hydraulic system components (hoses, cylinders, etc.) before reconnecting them to the pump. This will prevent contaminated oil from re-entering the pump. 4.5 Refilling The Reservoir 4.3 Inspecting The Hydraulic Fluid Level CAUTION: Always disconnect air supply before all maintenance. 1. Check the oil level in the reservoir after every 10 hours of use. 2. The oil level should come to within 1/2" of the filler plug with all hoses attached. 3. Drain and replenish the reservoir with an approved, high-grade hydraulic oil such as OTC 16355 after every 300 hours of use. Hoses: Hydraulic hoses on this unit carry a rating of 10,000 PSI. Replacement hoses must carry the same rating. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 CAUTION: Always disconnect air supply before all maintenance. 1. If additional oil must be added to the reservoir, use only an approved high-grade hydraulic oil such as OTC 16355 (215 SSU @ 100 F). 2. Clean the entire area around the filler plug before adding oil to the reservoir. 3. Remove the filler plug and insert a clean funnel with filter. 4. The ram must be fully retracted and the air supply disconnected when adding the oil to the reservoir. UNCONTROLLED COPY Page 21 of 30 Hydraulic Press Assembly 4.6 Venting the Reservoir To improve oil delivery and increase useable oil capacity, vent the reservoir by removing the vent screw from the filler plug before using the pump. See Figure 4-1. 3. Remove the screwdriver and depress the pump end of the pedal once more. 4. If the ram extends or pressure builds, the pump has been sucessfully primed. 5. If the pump does not respond, repeat the procedure, repeatedly jogging the air intake valve while holding the pedal in the RELEASE position. 4.8 Periodic Cleaning CAUTION: Always disconnect air supply before all maintenance. VENT SCREW A routine should be established to keep the pump as free from dirt as possible. Figure 4-1 4.7 Priming the Pump Unit If the pump unit must be primed, perform the following procedure: 1. Depress the release end of the pedal while holding down the air intake valve with a flathead screwdriver. The air intake valve is located directly under the pedal in the area marked PUMP. This "button" is depressed simultaneously with the RELEASE area of the pedal during priming. 1. All unused couplers should be sealed with thread protectors. 2. All hose connections must be free of grit and grime. 3. Any equipment hooked up to the pump should also be kept clean. 4. Use only approved, clean hydraulic oil, such as OTC 16355 in this unit and change as recommended (every 300 hours). An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your 19286-1000 or use this as a template to create you own schedule or use your company's standard chart, if applicable. 2. Allow the pump to cycle approximately 15 seconds. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 22 of 30 Hydraulic Press Assembly Preventive Maintenance Chart Daily: Clean. See Section 5.5. As Required: Lubricate. See Section 5.1. CHECK SHEET MONTH Week YEAR _________ Daily Use Days of the Week MON TUE WED THU FRI SAT SUN Solution 1 2 3 4 Lubrication Change Hydraulic oil Bleeding Air From the System 1 drop per minute into the system Use SAE No. 10 Oil 300 Hours Use OTC 16355 After prolong use Refilling Reservoir 10 hours or when needed Cleaning Hose connections free of grit and dirt. Pump kept clean Run the system thru several cycles. Use 215 SSU@100F (otc 16355) Use soft cloth Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the tool. 4.9 Spare Parts Customers are responsible for maintaining the tool. Spare parts are available from Molex. Moving and functioning parts can be damaged or wear out over time and will require replacement. Molex recommends that the customer keep some or all of them in stock to reduce production down time. 4.10 Perishable Parts (Tool Kits) Customers are responsible for maintaining the 19286-1000. Perishable parts are those parts that come in contact with the product and will wear out over time. Molex recommends that all customers keep at least one set of the perishable tooling in stock at all times. This will reduce the amount of production down time. 4.11 Storage When storing the 19286-1000 assembly, disconnect the air supply and store in a dry location. If the pump is disconnected from the hydraulic head, reinstall the dust cap on the cylinder inlet. When transporting, reinstall the red-vented cap on the pump reservoir. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 23 of 30 Hydraulic Press Assembly Section 5 5.1. Parts Lists and Assembly Drawing 5.2. Troubleshooting Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 24 of 30 Hydraulic Press Assembly 5.1 19286-1000 Main Parts List and Assembly Drawings 19286-1000 - Hydraulic Press Assembly Figure 6-1 Item Order No. Description Qty 1 19286-0051 C-FrameStand Assembly 1 (Figure 5-2) 2 19286-0117 Putt Pump Hydraulic Head Crimper 1 (Figure 5-3) 3 19286-0300 Terminal Locator Assembly 1 (Figure 5-4) 2 1 2 1 Figure 5-1 3 Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 25 of 30 Hydraulic Press Assembly 5.1 19286-0051 Parts List and Assembly Drawing 19286-0051 - C-Frame Stand Assembly Figure 5-2 Item Order No. Description Quantity 1 19286-0302 Side Guard 1 2 19286-0304 Front Guard 1 3 19286-0310 Left Side Guard 1 4 19286-0311 Mounting Bracket 4 5 19286-0400 Guard Assembly (All parts listed) 0 6 19286-0401 Adapter Plate 4 7 19286-0402 Spacer Plate 1 8 19286-0126 Right Plate 1 9 19286-0127 Left Plate 1 10 19286-0128 Base Plate 1 11 19286-0129 Back Plate 1 12 63600-1863 Thumb Screw 3 13 N/A M5 by 10 Long SHCS 12** 14 N/A M6 by 30 Long SHCS 8** ** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270). 13 (4) 3 14 8 11 (4) 9 12 (3) 6 (4) 7 13 4 (4) 14 (4) (4) 10 2 1 Figure 5-2 13 Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY (4) Page 26 of 30 Hydraulic Press Assembly 5.2 19286-0117 Parts List and Assembly Drawing 19286-0117 - Main Assembly Figure 5-3 Item Order No. Description 4 19286-0041 Hydraulic Hose Assembly-6 Feet 5 19286-0049 Filter Regulator with Gauge 6 19286-0059 Putt Pump Power Unit 7 19286-0103 Air Hose 1/4 NPT Male Fitting-10 Feet 8 19286-0051 C-Frame Stand Assembly 9 19286-0005 Hydraulic Head Assembly 10 19286-0006 HHLS Tool Holder Order separately Qty 1 1 1 1 Optional 1 2 2 4 1 6 3 7 5 Figure 5-3 Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 27 of 30 Hydraulic Press Assembly 5.3 19286-0300 Parts List and Assembly Drawing 19286-0300 - Terminal Locator Assembly Figure 5-3 Item Order No. Description Quantity 1 11-21-5694 (AM8921-221) Compression Spring 2 2 19286-0301 Stop Receptacle 1 3 19286-0306 Terminal Stop Retainer 1 4 19286-0307 Stop Plug 1 5 19286-0308 Frame Stop 1 6 19286-0309 Locking Block 1 7 19286-0312 Terminal Stripper Bar 2 8 19286-0313 Filler Bar 1 9 N/A M3 by 8 long SHCS 2** 10 N/A M5 by 18 long SHCS 4** 11 N/A M5 by 25 long SHCS 4** 12 N/A M6 by 20 long SHCS 2** 13 N/A M5 Flat Washer 4** ** The following purchased parts are available from an Industrial supply company such as MSC (1-800-645-7270). 19286-0051 REF 2 4 (2) 7 11 (4) 5 12 (4) (2) 3 13 9 10 (2) 1 (2) 8 (2) 6 10 Figure 5-3 (2) Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 28 of 30 Hydraulic Press Assembly 5.4 Troubleshooting Symptom Pump reciprocates but no oil delivery. (Ram will not extend) Low oil delivery. (Ram extends slowly) Pump will not build to maximum Pressure. (No visible leakage) Pump builds pressure but will not hold system pressure. Cause Low oil level. Pump not primed. Check oil filter for contamination. Reservoir not vented Inadequate air supply: 1. Check air input supply. 2. Contamination, check airside of pump. Thoroughly inspect the slot in the air cylinder tub. Solution Replenish oil reservoir. Depress air intake valve and hydraulic release valve simultaneously. Invert pump. Fill intake filter with oil. Depress pedal end marked "pump. Remove filter and clean. 1. Should be 20 CFM mininum. 2. Clean and reassemble. Hydraulic failure: 1. Check the oil filter forcontamination. 2. Air in hydraulic system. 1. Clean and reinstall. 2. Bleed the system as described in "Preventative Maintenance" Section. Check the air supply. 100 PSI is required to obtain maximum pressure. Check hydraulic connections. Refit as needed. Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 29 of 30 Hydraulic Press Assembly For more information use the Crimping Testing and Inspection Handbook for Industrial (Closed Barrel products). There is no charge for this book, which can be found on the Molex Website (www.molex.com) or contact you local Molex sales engineer. Visit our Web site at http://www.molex.com Doc No. TM-192861000 Release Date: 10-12-12 Revision: A Revision Date: 10-12-12 UNCONTROLLED COPY Page 30 of 30