molex MagKrimp 19078-0122, Operation Manual

Page 1: ...ED COPY Page 1 of 22 Revision A Revision Date 03 21 14 MagKrimp Hydraulic Head Crimper With Optional Bench 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 ...

Page 2: ... 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...

Page 3: ...y also be used to alert against unsafe practices associated with events that could lead to personal injury WARNING 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 ...

Page 4: ...ire 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 ...

Page 5: ... 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...

Page 6: ...mper Doc No TM 190780422 Release Date 03 28 14 UNCONTROLLED COPY Page 6 of 22 Revision A Revision Date 03 28 14 Section 1 General Description 1 1 Description 1 2 Features 1 3 Technical Specifications 1 4 Delivery Check 1 5 Tools ...

Page 7: ...ROLLED COPY Page 7 of 22 Revision A Revision Date 03 28 14 Figure 1 1 AIR HOSE HYDRAULIC HOSE ASSEMBLY FILTER REGULATOR GAUGE HYDRAULIC HEAD ASSEMBLY VENTED CAP RESERVOIR UNIT C FRAME STAND ASSEMBLY OPTIONAL PUTT PUMP POWER UNIT DUST CAP Principal Mechanical Parts of the 19078 0422 ...

Page 8: ...ication 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 Weight 5 4kg 12lbs 1 4 Delivery Check 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 fil...

Page 9: ...per Doc No TM 190780422 Release Date 03 28 14 UNCONTROLLED COPY Page 9 of 22 Revision A Revision Date 03 28 14 Section 2 Set Up and Adjustments 2 1 Air Supply Hook up 2 2 Connection and Bench Mounting 2 3 Installation of Tool Kits ...

Page 10: ...p 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 ou...

Page 11: ...is marked on each die See Section 3 3 CAUTION Be sure to use the correct pair of dies for the appropriate wire and terminal 3 The anvil and punch tool kit is installed in the tool from either side one at a time To install the punch lift the release knob until the tool holder pin is fully withdrawn from the holder cavity Slide the punch nest into the lower tool holder until it is centered Release t...

Page 12: ... Doc No TM 190780422 Release Date 03 28 14 UNCONTROLLED COPY Page 12 of 22 Revision A Revision Date 03 28 14 Section 3 Terminal Specifications and Crimping Operation 3 2 Scope 3 3 Terminal Specifications Chart 3 4 Crimping Terminals ...

Page 13: ...numbers and types of wire 3 Position the terminal and wires into the center of the punch Nest centering the terminal barrel with the tooling See Figure 3 1 and 3 2 4 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 onto the wires The pump will stop when maximum pressure is reached 5 Aft...

Page 14: ...6 6 25 234 5 94 Blue 1 19078 0131 19195 1021 246 6 25 234 5 94 Blue 1 19078 0131 19195 1037 246 6 25 234 5 94 Blue 1 19078 0131 19195 1011 246 6 25 234 5 94 Blue 1 19078 0131 19195 1019 246 6 25 234 5 94 Blue 1 19078 0132 19195 1027 470 11 93 464 11 79 20 760 104 960 12 2 10 16 2 54 4 06 10 26 2 54 6 60 Green 1 19078 0132 19195 1056 470 11 93 464 11 79 Green 1 19078 0132 19195 1085 470 11 93 464 1...

Page 15: ...ate 03 28 14 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 ...

Page 16: ...r 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 45 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 th...

Page 17: ... 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 pressure supply before all maintenance A routine should be ...

Page 18: ...ventive 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 f...

Page 19: ...gKrimp Hydraulic Head Crimper Doc No TM 190780422 Release Date 03 28 14 UNCONTROLLED COPY Page 19 of 22 Revision A Revision Date 03 28 14 Section 5 5 1 Parts Lists and Assembly Drawing 5 2 Troubleshooting ...

Page 20: ... Assembly Drawings 19078 0422 Main Assembly Figure 5 1 Item Order No Description Quantity 1 19286 0041 Hydraulic Hose Assembly 6 Feet 1 2 19286 0049 Filter Regulator with Gauge 1 3 19286 0059 Air Hydraulic Pump Power Unit 1 4 19286 0103 Air Hose 1 4 NPT Male Fitting 10 Feet 1 5 19078 0429 Hydraulic Head Assembly for U dies 1 6 19286 0600 C Frame Stand Assembly Optional Order separately ...

Page 21: ... Low oil delivery Ram extends slowly Reservoir not vented Remove filter and clean Inadequate air supply 1 Check air input supply 2 Contamination check airside of pump Thoroughly inspect the slot in the air cylinder tub 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 des...

Page 22: ...vision A Revision Date 03 28 14 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 ...