molex 19286-1000 User manual
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 1 of 30
Revision A Revision Date 10-12-12
Hydraulic Press Assembly
Operation Manual
Order No 19286-1000
Description
Operation
Maintenance
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 2 of 30
Revision A Revision Date 10-12-12
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
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
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
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.
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 3 of 30
Revision A Revision Date 10-12-12
WARNING
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
W
ARNING
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.
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 4 of 30
Revision A Revision Date 10-12-12
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. 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
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 5 of 30
Revision A Revision Date 10-12-12
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
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 6 of 30
Revision A Revision Date 10-12-12
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
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 7 of 30
Revision A Revision Date 10-12-12
Section 1
General Description
1.1. Description
1.2. Features
1.3. Technical Specifications
1.4. Delivery Check
1.5. Tools
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 8 of 30
Revision A Revision Date 10-12-12
Figure 1
-
1
AIR
HOSE
HYDRAULIC HOSE
ASSEMBLY
FILTER
REGULATOR
GAUGE
HYDRAULIC
HEAD
ASSEMBLY
VENTED CAP
RESERVOIR
UNIT
C
-
FRAM
E STAND
ASSEMBLY
PUTT PUMP
POWER UNIT
CRIMP DIES
TERMINAL
LOCATOR
ASSEMBLY
Principal Mechanical Parts of the 19286-1000
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 9 of 30
Revision A Revision Date 10-12-12
General Description
1 1 Description
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.
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.
1 2 Features
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
Pneumatic
Supply Pressure 100 PSI (6.9 Bars)
125-PSI max. (8.6 Bars max.)
Cycle Time 15 seconds
1 4 Delivery Check
Carefully remove the Molex Hydraulic Press
Assembly from its shipping container and
determine that the following items are included in
the package.
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)
Operation Manual ATS-192861000
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
Hydraulic Press Assembly
Doc No. TM-192861000 Release Date 10-12-12 UNCONTROLLED COPY Page 10 of 30
Revision A Revision Date 10-12-12
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
Table of contents
Other molex Power Tools manuals
molex
molex 63811-3300 User manual
molex
molex 63819-3200 User manual
molex
molex 63819-7300 User manual
molex
molex 43375 User manual
molex
molex 63811-0300 User manual
molex
molex 11-31-6356 User manual
molex
molex TM2000 User manual
molex
molex 207129 Series User manual
molex
molex 57131-6000 User manual
molex
molex TM-3000 User manual
molex
molex TM42 User manual
molex
molex 63600-0478 User manual
molex
molex 63801-8550 User manual
molex
molex 63816-0200 User manual
molex
molex TM-3000 User manual
molex
molex 63816-0100 Manual
molex
molex 63827-2000 User manual
molex
molex 63827-8800 User manual
molex
molex 63823-5700 User manual
molex
molex RHT 2251 User manual
