Molex MagKrimp 19078-0422 Manuel utilisateur

MagKrimp™ Hydraulic Head Crimper

Doc No. TM-190780422 elease Date: 03-21-14 UNCONTROLLED COPY Page 1 of 22

evision: A evision Date: 03-21-14

MagKrimp™ Hydraulic Head Crimper

(Wit Optional Benc Mounting)

Operation Manual

Order No. 19078-0422

For MagKrimp



 Products Taps, Butt, and Parallel Splices and Terminals

(Up to 230,000 Circular Mill Area)

 Description

 Operation

 Maintenance

MagKrimp™ Hydraulic Head Crimper

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Table of Contents

Contents

MagKrimp™ Hydraulic Head Crimper ........................................................................................................................... 1

Order No. 19078-0422 ................................................................................................................................................... 1

Safety Warnings and Information .............................................................................................................................. 3

Section 1 ....................................................................................................................................................................... 6

General Description .................................................................................................................................................. 6

Principal Mechanical Parts of the 19078-0422 .......................................................................................................... 7

General Description .................................................................................................................................................. 8

1.1 Description .................................................................................................................................................... 8

1.2 Features ........................................................................................................................................................ 8

1.3 Technical Specification .................................................................................................................................. 8

1.4 Delivery Check .............................................................................................................................................. 8

1.5 Tools .............................................................................................................................................................. 8

Section 2 ....................................................................................................................................................................... 9

Set-Up and Adjustments ........................................................................................................................................... 9

2.1 Set-Up ......................................................................................................................................................... 10

2.2 Hydraulic Connections and Optional Bench Mounting ................................................................................. 10

2.3 Installation of Tool Kits ................................................................................................................................ 11

Section 3 ..................................................................................................................................................................... 12

Terminal Specifications and Crimping Operation .................................................................................................... 12

3.1 SCOPE ........................................................................................................................................................ 13

3.2 Crimping Terminals ..................................................................................................................................... 13

3.3 Crimping Tool Go-No Go Charts ................................................................................................................. 14

Section 4 ..................................................................................................................................................................... 15

4.1 Lubrication ................................................................................................................................................... 16

4.2 Bleeding Air From The System .................................................................................................................... 16

4.3 Inspecting The Hydraulic Fluid Level ........................................................................................................... 16

45.4 Draining and Flushing the eservoir ........................................................................................................... 16

4.5 efilling The eservoir ................................................................................................................................ 16

4.6 Venting the eservoir .................................................................................................................................. 17

4.7 Priming the Pump Unit ................................................................................................................................. 17

4.8 Periodic Cleaning ........................................................................................................................................ 17

4.9 Spare Parts ................................................................................................................................................. 18

4.10 Perishable Parts (Tool Kits) ......................................................................................................................... 18

4.11 Storage ........................................................................................................................................................ 18

Section 5 ..................................................................................................................................................................... 19

5.1 Main Parts List and Assembly Drawings ..................................................................................................... 20

5.2 Troubleshooting ........................................................................................................................................... 21

MagKrimp™ Hydraulic Head Crimper

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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.

eplacement 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.

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 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.

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

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.

Always wear proper ear protection

when Operating or servicing this applicator.

Failure to observe these precautions may result in

Injury or property damage.

MagKrimp™ Hydraulic Head Crimper

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WARNING

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.

Do not use

compressed air to clean

this equipment.

The forces created by compressed

air can force debris into the tool.

Failure to observe these precautions may

result in injury or property damage.

Air

Hydraulic

Pump

WARNING

Pump

WARNING

Hand/Foot Operated

Maximum Capacity: 10,000 PSI

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

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.

Never attempt to grasp a leaking hose under pressure

with your hands. The force of escaping hydraulic fluid

could cause serious injury.

Do not subject the hose to potential hazard such as fire,

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.

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.

Never paint the couplers. Hose deterioration due to

corrosive materials may result in possible personal injury

Do not exceed the PSI hydraulic rating noted

on the pump nameplate or tamper with the

internal high-pressure relief valve.

Creating pressure beyond rated capacities

may result in personal injury.

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.

Cylinder

WARNING

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.

Air

Supply

WARNING

Shut off and disconnect the air supply when

the pump is not in use or before breaking

any connection in the system.

MagKrimp™ Hydraulic Head Crimper

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WARNING

MOLEX CANNOT BE RESPONSIBLE FOR DAMAGE OR INJURY RESULTING FROM UNSAFE PRODUCT

USE, LACK OF MAINTENANCE, OR INCORRECT PRODUCT AND SYSTEM APPLICATION.

CAUTION

ilure 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 Tec nical 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 epresentative.

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. Customer name

2. Customer address

3. Person to contact such as (name, title, e-mail, and telephone number

4. Press order number (Lease number also if applicable)

5. Serial number (Lease number also if applicable)

6. Molex Connector product order number

7. Urgency of request

8. 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

MagKrimp™ Hydraulic Head Crimper

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Section 1

General Description

1.1. Description

1.2. Features

1.3. Technical Specifications

1.4. Delivery Check

1.5. Tools

MagKrimp™ Hydraulic Head Crimper

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Figure 1-1

AIR HOSE

HYDRAULIC HOSE

ASSEMBLY

FILTER

REGULATOR

GAUGE

HYDRAULIC

HEAD

ASSEMBLY

VENTED CAP

RESERVOIR

UNIT

FRAME STAND

ASSEMBLY

(OPTIONAL)

PUTT PUMP

POWER UNIT

DUST CAP

Principal Mec anical Parts of t e 19078-0422

MagKrimp™ Hydraulic Head Crimper

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General Description

1.1 Description

The Molex Putt Pump Hydraulic Head Crimper is

designed to crimp the Molex MagKrimp

Product line.

1.2 Features

 Crimps the whole MagKrimp family with

interchangeable tool kits, which reduce the

overall cost and provide production flexibility.

 Crimping dies are easily and quickly

interchanged to reduce production down time.

 Complete portable system that allows tool to be

moved and stored easily.

 Tool may be used as a Potable tool, suspended

over head or bench mounted.

1.3 Tec nical Specification

Pneumatic:

Supply Pressure: 100 PSI (6.9 Bars)

125-PSI max. (8.6 Bars Max.)

Crimping Pressure 24,000 LBS. Max.

Hydraulic Pressure: 10,000 PSI Max.

Cycle Time:

15 seconds

Weig t

5.4kg (12lbs)

1.4 Delivery C eck

Carefully remove the Putt Pump Hydraulic Head

from its shipping container and determine that the

following items are included in the package.

 Hydraulic Head Crimper Tool

 Pump Assembly with hoses, filter, regulator,

and gauge assembly (Includes vented cap for

pump)

 TM-190780422 Instruction Manual

1.5 Tools

The following tools are recommended for setup

and adjustments to this tool.

1. Metric standard hex wrench set

2. Inch standard hex wrench set

3. Adjustable wrench

4. Wire stripper / cutter

5. Screw driver

Can Also Be Used Wit :

19078-0160 Electric Hydraulic Pump with Foot

Switch

19286-0041 Hydraulic Hose Assembly 6 foot

19286-0042 Hydraulic Hose Assembly 10 foot

MagKrimp™ Hydraulic Head Crimper

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Section 2

Set-Up and Adjustments

2.1. Air Supply Hook up

2.2. Connection and Bench Mounting

2.3. Installation of Tool Kits

MagKrimp™ Hydraulic Head Crimper

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Figure

AIR SUPPLY

CUSTOMER

SUPPLIED

FILTER, REGULATOR

AND GAUGE

LUBRICATOR

(OPTIONAL)

AIR HOSE

FILTER CAP: RED FOR

SHIPPING AND BLACK

(VENTED) FOR OPERATION

PUMP

DUST CAP

HYDRAULIC HOSE

QUICK DISCONNECT

COUPLER

HYDRAULIC HEAD

ASSEMBLY

CAUTION: Always disconnect the air supply until the system is ready to operate.

2.1 Set-Up

The principal mechanical parts of the 19078-0422 are illustrated in Figure 1-1 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. emove 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 2-1.

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.

2.2 Hydraulic Connections and Optional Benc Mounting

1. emove the dust cap from the cylinder on the crimp head.

2. Connect the quick disconnect coupler onto the cylinder inlet on the

crimp head. See figure 2-1.

3. eplace the red filler cap on the pump reservoir with the black-vented

cap that is supplied with the unit.

4. To mount the hydraulic head assembly to the optional C-Frame stand,

loosen the three thumbscrews in the stand and place the hydraulic

head in the stand with the cylinder facing up. Tighten the

thumbscrews; making sure the hydraulic head is securely positioned.

See Figure 2-2.

FRAME

STAND

HYDRAULIC

HEAD

Figure 2

THUMB

SCREW (3)

Ce manuel convient aux modèles suivants

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