TE Connectivity 69120-1 Reference guide

Customer Manual
1 of 22
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PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
409-1950
8 DEC 20 Rev G
SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!......................................2
1. INTRODUCTION ..................................................................................................................3
2. DESCRIPTION .....................................................................................................................4
2.1.Physical..........................................................................................................................4
2.2.Functional.......................................................................................................................4
2.3.Specifications .................................................................................................................4
2.4.Accessories....................................................................................................................7
3. RECEIVING INSPECTION .................................................................................................10
4. SETUP................................................................................................................................10
4.1.Installing the Casters....................................................................................................10
4.2.Filling the Hydraulic Fluid Reservoir.............................................................................11
4.3.Preparing the Hydraulic Connections...........................................................................11
4.4.Connecting the Accessories.........................................................................................12
4.5.Disconnecting Accessories ..........................................................................................14
5. OPERATING PROCEDURE ..............................................................................................15
5.1.Precautions ..................................................................................................................15
5.2.Crimping.......................................................................................................................16
6. MAINTENANCE AND INSPECTION .................................................................................17
6.1.Storage.........................................................................................................................18
6.2.Hydraulic Fluid Reservoir .............................................................................................18
6.3.Bleeding Air from Hydraulic System.............................................................................19
6.4.Checking Hydraulic Pressure.......................................................................................20
6.5.Checking and Replacing Brush Assembly on Universal Motor ....................................21
7. DISPOSAL .........................................................................................................................21
8. REPLACEMENT AND REPAIR .........................................................................................22
9. RESTRICTION ON HAZARDOUS SUBSTANCES (RoHS) INFORMATION....................22
10. REVISION SUMMARY .......................................................................................................22
Heavy Duty Electric
Hydraulic Pumps
PN 69120-1 and 69120-2
ORIGINAL INSTRUCTIONS

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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
Always wear approved eye protection while operating
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. Always keep guards in
place during normal operation.
Electrical shock hazard.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the equipment.
Read and understand the entire manual before using
the tool.
Two people are required to lift the pump.
SUPPORT CENTER
CALL TOLL FREE 1-800-522-6752 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Support Center offers a means of providing technical assistance when required. In addition, Field Service
Specialists are available to provide assistance in the adjustment or repair of the application equipment when
problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE SUPPORT CENTER
When calling the Support Center regarding service to equipment, 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
avoided in this manner.
When calling the Support Center, be ready with the following information:
1.
Customer name
6.
Product part number (and serial number
if applicable)
2.
Customer address
7.
Urgency of request
3.
Person to contact (name, title,
telephone number, and extension(
8.
Nature of problem
4.
Person calling
9.
Description of inoperative components
5.
Equipment number (and serial number
if applicable)
10.
Additional information/comments that
may be helpful

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Figure 1: Heavy-duty electric hydraulic pump
1. INTRODUCTION
Each heavy-duty electric hydraulic pump (shown in Figure 1) is a portable power source that uses a handle
control or foot control to activate the unit. The unit combines the convenience of a hand tool with the power of a
large machine used for the application of terminals and splices onto large wire sizes. Quick-disconnect
couplers are used to install a hydraulic hose and crimping head (available separately) to the pump to form a
complete unit.
Read the following instructions carefully before operating the unit. The performance of the unit depends largely
on information contained in this customer manual and operator training and skill.
When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
DANGER
Denotes an imminent hazard that may result in moderate or severe injury.
CAUTION
Denotes a condition that may result in product or equipment damage.
NOTE
Highlights special or important information.
NOTE
Dimensions in this customer manual are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.
Reasons for reissue of this customer manual are provided in Section 10, REVISION SUMMARY.

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2. DESCRIPTION
2.1. Physical
The pump is a two-stage hydraulic pumping unit. It is driven by a universal motor connected to a gear pump for
the low-pressure stage and a five-cylinder axial piston pump (supercharged by the gear pump) for the high-
pressure stage. The pump features a hydraulic fluid reservoir and pressure regulation and control devices.
The hydraulic connection is fitted with a thread protector cap to prevent the threads of the quick-disconnect
coupler from being damaged and to prevent contamination of the quick-disconnect coupler.
The pump features a pilot lamp (69120-1 only) that illuminates to indicate that the pump is activated.
The pump includes casters (one for each corner) that can be installed onto the pump for portable applications.
For pump specifications, see section 2.3.
The date code is marked on a metal tag attached to the body of the pump. The date code is in the format
YYWW, where YY represents the year of the manufacture, and WW represents the week of manufacture. For
example, if the date code marked on a tool is 2133, the tool was made in the 33rd week of 2021.
2.2. Functional
Before each cycle can be started, the RESET switch (of the handle control or foot control) must be depressed.
When the RESET switch is depressed, the pilot lamp (69120-1 only) of the pump illuminates.
When the RUN switch is depressed and held, the pump completes a cycle. When the RUN switch is depressed
momentarily, the cylinder of the crimping heads partially advances and the dies partially close for a moment.
When the DUMP switch is depressed, the cylinders retract, the dies open fully, and the pressure is released
from the system.
When maximum hydraulic pressure is reached, the motor shuts OFF, and all pressure is automatically released
from the system.
This pump is not for use in applications other than crimping. Examples of improper use include work holding,
cutting, bending, and lifting applications.
2.3. Specifications
Table 1: Dimensions
Height
464 mm [18.25 in.]
Width
241 mm [9.50 in.]
Length
292 mm [11.50 in.]
Net weight
(with oil to capacity)
28 kg [62 lb] without hydraulic fluid
35 kg [78 lb] with 2 gallons of hydraulic fluid
Table 2: Electrical requirements
Pump
Voltage
69120-1
115 V
69120-2
220 V

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Table 3: Oil delivery rate
Oil pressure
Oil delivery per minute
Bar
PSI
Liters
Cubic inches
7
100
10.7
650
69
1000
1.3
80
345
5000
1.1
70
579
8400
0.9
55
Figure 2 shows the oil delivery rate at different pressure levels.
Figure 2: Performance curve for oil pressure vs. volume

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Table 4: Other specifications
Motor
839 W [11/8 hp]
50-60 Hz, single phase
8400 rpm
Current draw (max)
14 A (15 A circuit breaker)
Noise (at idle and max pressure
output)
90-95 dBA
Pressure output
579 bar [8400 psi] max
Reservoir capacity
7.57 liters [2 gallons]
Pressure switch setting
552-579 bar [8000-8400 psi]
Relief valve setting
586-600 bar [8500-8700 psi]
Voltage drop
0.2 V for a 3 m [10 ft] power cord
Temperature range for operation
-20º to 50º C [-4º to 122º F]
Hydraulic hose life
5 years*
Interrupting capacity
5000 A
*Replace earlier if signs of excessive wear or damage occur.

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2.4. Accessories
The accessories for the pump shown in Figure 3 are available separately.
The pump accepts interchangeable crimping heads, and the crimping heads accept interchangeable die
assemblies, except Crimping Head 69069 (which has self-contained dies). Use of a latch pin kit eliminates the
possibility of misplacing the standard latch pin supplied with the crimping head.
The handle control and foot control are available to operate the crimping head. If the pump is used in portable
applications, the handle control may be preferable. The handle control is available with or without a hose
assembly. The handle control is connected to the pump hydraulically (by the hose or use of the hose assembly)
and electrically (by the cordset), and the crimping head is connected to the handle control. If the pump is used
in stationary applications, the foot control may be preferable. The foot control is connected to the pump
electrically, and the crimping head is connected to the pump hydraulically (by use of the hose assembly).
The multi-directional valve allows more than one crimping head (a maximum of three or six is available) to be
operated from the pump. A separate hose assembly is needed to connect each crimping head to the multi-
directional valve and to connect the multi-directional valve to the pump. The multi-directional valve can only be
operated by the foot control.
Refer to the following paragraphs for part numbers and descriptions.
Figure 3: Accessories

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Hydraulic Handle Control Assembly
The handle control assembly consists of a handle grip, an outlet with a female quick-disconnect coupler
and protector cap, and a cordset. It is available with or without a hose assembly. The handle control is
operated by three switches (marked RUN, DUMP, and RESET).
Table 5: Hydraulic handle control assembly part numbers
Hydraulic handle
control assembly
Length (m [ft])
Description
59907-7
2.1 [7]
With hose assembly
(hose and cordset)
1-59907-5
4.6 [15]
2-59907-1
6.4 [21]
2-59907-8
8.5 [28]
1-59908-5
4.6 [15]
Without hose assembly
(cordset)
2-59908-1
6.4 [21]
Hydraulic Hose Assembly
The hose assembly is a hose with male quick-disconnect coupler and protector cap on each end.
Table 6: Hydraulic hose assembly part numbers
Hydraulic hose
assembly
Length (m [ft])
59909-3
1.0 [3]
59909-7
2.1 [7]
1-59909-5
4.6 [15]
2-59909-1
6.4 [21]
NOTE
The date of manufacture of the hose is marked on the hose in the format MM-YYYY. MM represents the month of manufacture
and YYYY represents the year. The hose should be replaced after five years.
Foot Control
The foot control consists of base with a guard and a cordset. The foot control is operated by three pedals
(marked RUN, DUMP, and RESET).
Table 7: Foot control part number
Foot control
Cordset length (m [ft])
68284-1
4.6 [15]

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Multi-Directional Valve
The multi-directional valve features a manual handle control and outlets to connect more than one head to
the pump (up to three or six is available). The valve can only be operated by the foot control. Installation
and operating procedures are provided in the instruction sheet packaged with the valve.
Table 8: Multi-directional valve part numbers
Multi-directional valve
Description
Instruction sheet
59220
3-way
408-1200
59221
6-way
Crimping Head
Acceptable crimping heads, applicable products, and wire size range are listed below. Applicable die
assembly part numbers and installation instructions are provided in the instruction sheet packaged with
the crimping head.
Table 9: Crimping head part numbers
Crimping
head
Instruction
sheet
Product
Wire size range
68073-2
408-2449
AMPOWER* and COPALUM* terminals and splices
4/0 AWG-1500 MCM
69051
408-2450
AMPLI-BOND*, PLASTI-GRIP*, and AMPOWER pre-
insulated terminals, and TERMINYL and COPALUM
terminals and splices
8-2 AWG
58445-1
408-9598
SOLISTRAND* terminals
250-600 MCM
69065
408-2452
AMPOWER, SOLISTRAND, and STRATO-THERM*
terminals and splices
8-4/0 AWG
69066
408-2453
AMPLI-BOND, PLASTI-GRIP heavy-duty, AMPOWER
pre-insulated and pre-insulated nylon heavy-duty
terminals, and TERMINYL and COPALUM sealed
terminals and splices
8-4/0 AWG
69067
408-2454
STRATO-THERM terminals and SOLISTRAND terminals
and splices
8-4/0 AWG
69069
408-1745
SOLISTRAND terminals and splices
8-2 AWG
69082
408-2456
Open barrel terminals and AMPOWER, SOLISTRAND,
and COPALUM terminals and splices
4/0 AWG-1000 MCM
TERMI-FOIL* end and center tap terminals
0.508-1.524
[.020-.060] thick foil
69097
408-2457
AMPOWER, SOLISTRAND, and STRATO-THERM*
post-insulated terminals and splices
6-2/0 AWG
69099
408-2458
AMPOWER quick-disconnect, COPALUM, TERMI-FOIL
single and double face terminals, and AMPOWER,
SOLISTRAND, and STRATO-THERM* post-insulated
terminals and splices
12-10 AWG-350
MCM
TERMI-FOIL end and center tap terminals
0.508-1.524
[.020-.060] thick foil
58422-1
408-9535
AMPLI-BOND, PLASTI-GRIP, AMPOWER pre-insulated
and pre-insulated nylon heavy-duty terminals and
COPALUM sealed and TERMINYL terminals and splices
8-4/0 AWG

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Latch pin kit
The latch pin kit consists of a latch pin, pivot pin, and coupling assembly. Assembly instructions are
provided in the instruction sheet packaged with the kit.
Table 10: Latch pin kit part numbers
Latch pin kit
Crimping head
Instruction sheet
67909
69051
408-2096
67909-2
69065
67909-3
69066
3. RECEIVING INSPECTION
1. Carefully inspect the pump upon arrival for evidence of damage that may have occurred in transit. If
damage is evident, file a claim against the carrier and notify TE Connectivity.
2. Check all components to make sure that they are secure.
3. Check all wiring for loose connections, cuts, or other possible causes of electrical short circuits.
4. Inspect all air lines for evidence of loose connections and cuts that may cause leakage.
4. SETUP
NOTE
Keep the pump in an upright position at all times.
4.1. Installing the Casters
Install the casters into the sockets in the bottom corners of the pump. The casters are not required unless the
pump is used in portable applications.
DANGER
Use the casters whenever possible while moving the pump. Two people are needed to lift the pump.

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4.2. Filling the Hydraulic Fluid Reservoir
The pump is shipped without oil in the hydraulic fluid reservoir. The proper oil to be used is included with the
pump in a separate container. Fill the reservoir as follows:
DANGER
Always use proper eye protection and oil-resistant gloves when handling hydraulic fluid.
1. Make sure that the pump is NOT CONNECTED to the power supply.
2. Ensure that the entire area around the oil filler hole is clean. Any dirt or dust caught in the oil could
damage the polished surfaces and precision-fit components of the pump.
3. Remove the oil filler cap
4. Using a clean funnel with a clean filter, pour the oil into the reservoir. The proper level is 12.7 mm
[0.50 in.] from the top of the oil filler hole.
5. NOTE
6. Use only an approved brand of hydraulic oil (see Table 12).
Table 11: Hydraulic oil specifications
Viscosity
grade
Viscosity @
38º C [100º F]
Pour point
Flash point
Fire
Specific
gravity
Neutral
number
Condrason
carbon
46
194-236 SSU
-29º C
[-20º F]
181º C
[357º F}
221º C
[430º F}
28
0.1 max
0.05%
Table 12: Approved brands of hydraulic oil
Brand
Manufacturer
Hydro-Drive HP 200
EF Houghton and Co.
DTE 25
Mobil Oil Co.
Tellus 46
Shell Oil Co.
Rando Oil HD 46
Texaco Inc.
NOTE
To check the oil level and refill the reservoir after initial set-up, refer to section 6.2.
4.3. Preparing the Hydraulic Connections
1. Clean the areas around the hydraulic connection (oil pod) of the pump and the crimping heads.
2. Clean the areas around all of the hose ends and quick-disconnect couplers.
3. Remove the protector cap from the quick-disconnect coupler of each accessory.
4. Remove the protector cap from the hydraulic connection of the pump.
5. Inspect the threads and fittings for signs of wear or damage, and replace them as needed.
6. Optional: Seal the hydraulic connections by coating the threads of the quick-disconnect couplers with a
high-grade, non-hardening sealant.
7. NOTE
A sealant is preferred, but PTFE tape can be used if only one layer of the tape is applied. If using the tape, apply it carefully to
prevent it from being pinched by the quick disconnect coupler and breaking off inside of the hose. Loose pieces of tape can
travel through the system and obstruct the flow of oil.

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4.4. Connecting the Accessories
CAUTION
Before installing any accessories, make sure the pump is DISCONNECTED from the power supply.
Make sure that all coupling areas of the accessories being used are thoroughly clean.
If Using the Handle Control
1. Attach the hose assembly.
If using the handle control without a hose assembly included, attach one end of the hose
assembly to the handle control and the other end to the pump (Figure 4).
If using the handle control with a hose assembly included, attach the hose assembly to the
pump (Figure 5).
2. Mate the quick-disconnect couplers and tighten the collar.
3. Attach the crimping head to the handle control according to the instructions included with the
crimping head.
4. Plug the handle control into the pump.
5. If the crimping head does not contain dies, install a die assembly onto the crimping head
according to the instructions included with the crimping head.
Figure 4: Using the handle control without a hose assembly included
Figure 5: Using the handle control with a hose assembly included

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If Using the Foot Control
Refer to Figure 6.
1. Attach one end of the hose assembly to the pump. Mate the quick-disconnect couplers and
tighten the collar.
2. Attach the other end of the hose assembly to the crimping head according to the instructions
included with the crimping head.
3. Plug the foot control into the pump.
4. If the crimping head does not contain dies, install a die assembly onto the crimping head
according to the instructions included with the crimping head.
Figure 6: Using the foot control

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If Using the Multi-Directional Valve (Foot Control Must Be Used)
Refer to Figure 7.
1. Attach one end of a hose assembly to the pump and the other end to the multi-directional valve.
2. Attach one end of each hose assembly to the multi-directional valve and the other end of each
hose assembly to a crimping head according to 408-1208.
3. Plug the foot control into the pump.
4. If any crimping head does not contain dies, install a die assembly onto the crimping head
according to the instructions included with the crimping head.
Figure 7: Using the multi-directional valve
4.5. Disconnecting Accessories
Before removing any accessory from the pump or a hose assembly, ALWAYS depress the DUMP switch to
release the pressure from the system, then DISCONNECT the pump from the power supply.
CAUTION
To avoid personal injury, ALWAYS release the pressure from the system, then DISCONNECT the pump from the power
supply before disconnecting an accessory from the pump or a hose assembly.
Protector caps are assembled onto crimping heads and hose fittings to prevent dit from entering the hydraulic
system. Ensure that protector caps are placed on quick-disconnect couplers when accessories are
disconnected.

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5. OPERATING PROCEDURE
5.1. Precautions
To avoid personal injury or damage to the pump or accessories, carefully observe the following precautions
before, during, and after operation of the pump.
For the power supply
DANGER
Ensure that the total current of the pumps being used matches the amperage of the electrical circuit being used.
DANGER
To avoid the possibility of fire, DO NOT attempt to increase the power line capacity by replacing a fuse with a fuse of higher
value.
DANGER
BEFORE operating the pump, ensure that the pump is properly grounded.
CAUTION
Make sure all hose connections are tightened, but not over-tightened. Connections should be secure and leak-free. Over-
tightening can cause permanent thread failure, or cause high-pressure fittings to split at pressures lower than their rated
capacities.
CAUTION
Make sure all hose connections are tightened, but not over-tightened. Connections should be secure and leak-free. Over-
tightening can cause permanent thread failure, or cause high-pressure fittings to split at pressures lower than their rated
capacities.
CAUTION
Oil flow must be unobstructed between the pump and the crimping head. Make sure that all couplers are fully mated and
tightened.
For the pump
DANGER
NEVER operate the pump without a hose assembly and crimping head attached to the pump.
DANGER
ALWAYS exercise caution when holding a terminal or splice near the crimping area.
DANGER
BEFORE changing the crimping head or die assembly or before disconnecting any connections from the pump, always
depress the DUMP switch to release the pressure from the system, then disconnect the pump from the power supply.
CAUTION
Ensure that protector caps are placed on the crimping head and hose fittings when they are disconnected.
For the hydraulic hose
DANGER
If the hydraulic hose ruptures or bursts, immediately depress the DUMP switch to release the pressure from the system, then
DISCONNECT the pump from the power supply.
DANGER
NEVER grab a leaking, pressurized hose. The force of escaping hydraulic fluid can cause serious injury.
CAUTION
To avoid damage to the hydraulic hose, DO NOT subject the hydraulic hose to potential hazards such as fire, sharp surfaces,
extreme heat or cold, or heavy impact. DO NOT let the hose kink, twist, curl, or bend so tightly that oil flow within the hose is
blocked or reduced.

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DANGER
DO NOT allow the hydraulic hose to contact corrosive materials such as creosote-impregnated objects and some paints.
Consult TE before painting a hose. NEVER paint the quick-disconnect couplers. Hose deterioration due to corrosive materials
can result in personal injury.
DANGER
DO NOT use the hydraulic hose to move attached accessories. Stress can damage the hose, causing personal injury.
5.2. Crimping
To crimp a terminal or splice, proceed as follows:
1. Plug the power cord of the pump into a properly grounded outlet. Refer to Table 2 for power source
requirements.
DANGER
NEVER use an ungrounded power supply for the pump.
DANGER
Stay clear of the crimping dies during the crimping process.
2. Strip the wires according to the instructions included with the crimping head or die assembly.
3. Depress the RESET switch. The pilot lamp on the pump illuminates (69120-1 only).
4. Depress the RUN switch momentarily to partially extend the cylinder of the crimping head. The dies
partially close. (The switches are marked on the handle control and on the foot control.)
5. Place the terminal or splice in the dies according to the instructions included with the crimping head or
die assembly.
6. Depress the RUN switch again to close the dies just enough to hold the terminal or splice in place. Then
release the switch. The dies remain partially closed only long enough for the wires to be inserted into
the wire barrel of the terminal or splice.
CAUTION
If the RUN switch is depressed too long, the dies close fully and crush the terminal or splice before the wires can be inserted.
7. If the dies fully close before the wires are inserted, depress the DUMP switch. The dies return to a
neutral position (partially open) without completing a cycle.
8. Insert the stripped wires into the wire barrel of the terminal or splice.
NOTE
If possible, insert the wires into both ends of a splice for the first crimp. If the first crimp is made with only the first wire
inserted, the wire for the second crimp may be more difficult to insert due to partial deformation of the wire barrel. Wire with
rectangular conductors should be oriented so that the crimping pressure is applied to the flat side of the conductors.
9. Depress the RUN switch until a cycle completes. Fully extend (dies close) and retract (dies open) the
cylinder.
10. Remove the crimped terminal or splice from the dies. Note that the trigger or pedal may be depressed,
but the pump does not start. Before the next crimp can be made, the RESET switch must be depressed.

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6. MAINTENANCE AND INSPECTION
It is important to establish a preventive maintenance and inspection program. Maintenance must be performed
at regular intervals to ensure efficient, dependable performance of the pump.
Maintenance should be performed in a dust-free area by a qualified technician. Any electrical work MUST be
performed by a qualified electrician.
DANGER
To prevent personal injury, ALWAYS depress the DUMP switch to release the pressure from the system, then DISCONNECT
the pump from the power supply before performing any maintenance or inspection procedure.
Keep the outer surfaces of the pump as free from dirt as possible.
Keep all hose connections free of dirt and grime.
Keep the breather hole of the oil filler cap clean and unobstructed at all times.
Keep all accessories that are connected to the pump clean.
Make sure that all unused quick-disconnect couplers are sealed with a protector cap.
NOTE
If applicable, check that the seals of the quick-disconnect couplers are not broken or worn. If seals are broken or worn, replace
them according to section 0.
Inspect the hydraulic hose and power cord for signs of wear after every eight hours of use. If
necessary, replace the hose.
If the power cord is damaged or wiring is exposed, replace or repair the power cord immediately.
Make sure that all voltages are wired for clockwise rotation.
A preventive maintenance and inspection program should include all of the procedures in sections 6.1 through
6.5.

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6.1. Storage
NEVER store the pump without having the protector cap installed or a hydraulic hose and crimping heads
attached to the hydraulic connection. The pump should be stored in a clean, dry area with low humidity
noncondensing). Check for proper pump function after storage.
6.2. Hydraulic Fluid Reservoir
Checking Oil Level and Refilling the Reservoir
CAUTION
Air can accumulate in the hydraulic system if the oil level is too low. This accumulation causes the cylinders to respond in an
unstable or slow manner.
Check the hydraulic oil level in the hydraulic fluid reservoir of the pump after each 10 hours of operating
the pump. Proceed as follows:
Depress the DUMP switch to fully retract the cylinders of the crimping heads.
Clean the entire area around the oil filler cap. Any dirt or dust caught in the oil could damage the
polished surfaces and precision-fit components of the pump.
Remove the oil filler cap. Check that the oil level is 12.7 mm [.50 in.] from the top of the oil filler hole.
If additional oil is needed, proceed as follows:
1. Depress the DUMP switch to release the pressure from the system, then DISCONNECT the pump
from the power supply. Make sure that the cylinders are retracted.
DANGER
The cylinders must be fully retracted before replenishing the oil. Overfills can cause personal injury due to excess reservoir
pressure created if the cylinders are not retracted.
2. Pour oil into the hydraulic fluid reservoir using a clean funnel with a filter. DO NOT exceed the
maximum capacity.
CAUTION
It is essential that the proper grade of oil be used. Refer to Figure 4.
3. Re-install the oil filler cap.
4. Connect the pump to the power supply, and cycle the pump (fully extend and retract the cylinders)
several times, ending with the cylinders retracted.

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Draining, Flushing, and Refilling the Hydraulic Fluid Reservoir
The frequency of oil changes depends upon the general working conditions, severity of use, and overall
cleanliness and care of the pump. It is recommended to drain, flush, and refill the reservoir of the pump
with an approved hydraulic oil after approximately every 300 hours of operating the pump as follows:
Depress the DUMP switch to release the pressure from the system, then DISCONNECT the pump from
the power supply.
NOTE
For 69120-2, drain the reservoir using the drain plug at the bottom of the reservoir.
Clean the pump exterior. The pump exterior must be clean before the motor and pump assembly is
removed from the hydraulic fluid reservoir.
Remove the 10 screws securing the motor and pump assembly to the hydraulic fluid reservoir. Remove
the motor and pump assembly.
CAUTION
BE CAREFUL not to damage the filter or any of the valves when lifting the motor and pump assembly off of the hydraulic fluid
reservoir. Refer to Figure 8.
Figure 8: Motor and pump assembly
5. Clean the inside of the reservoir. Rinse the filter until it is clean.
6. Fill the reservoir with approved, high-grade hydraulic oil (refer to Table 12).
7. Place the pump and motor assembly (with the gasket) on the reservoir, then install and evenly
tighten the 10 screws.
8. Connect the pump to the power supply, and cycle the pump (fully extend and retract the cylinders)
several times, ending with the cylinders retracted.
6.3. Bleeding Air from Hydraulic System
Air can accumulate in the system when the oil level becomes too low. The accumulation causes the cylinders
to respond in an unstable or slow manner. If this becomes evident, release the air from the system as follows:
1. Position the crimping heads so that the quick-disconnect coupler is facing UPWARD.
2. Depress the DUMP switch to release the pressure from the system. Make sure that the cylinder is fully
retracted. Then DISCONNECT the pump from the power supply.
3. Re-connect the pump to the power supply, then cycle the pump (fully extend and retract the cylinders)
several times, ending with the cylinders retracted.

409-1950
Rev G
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6.4. Checking Hydraulic Pressure
Check that the pump is functioning properly and reaching the proper pressure after every eight hours of use. If
necessary, adjust the pressure as follows:
1. Depress the DUMP switch to release the pressure from the system, then DISCONNECT the pump
from the power supply.
2. Remove the accessory from the hydraulic hose. Install a hydraulic pressure gage onto the end of the
hose.
3. Re-connect the pump to the power supply, and partially cycle the pump two or three times to bleed air
from the system.
4. Jog the pump through a cycle, then read the pressure level on the gage. If the gage reading is between
552 and 579 bar 18000 and 8400 psi], and the pump cycles properly, no adjustment of the pressure
switch is necessary.
If the reading is out of the required range, loosen the locknut on the pressure switch and turn the adjusting
screw clockwise to increase the pressure, or counter-clockwise to decrease the pressure. Turning the screw
half a rotation adjusts the pressure by one increment. Refer to Figure 9.
NOTE
The pressure switch should only be adjusted if the pump is not producing the desired pressure during crimping.
5. Holding the adjustment screw in place, tighten the locknut.
6. Actuate the pump to check the pressure setting. It might be necessary to make a second adjustment.
7. Depress the DUMP switch to release the pressure from the system, then DISCONNECT the pump
from the power supply. Remove the hydraulic pressure gage and reconnect the hose.
Figure 9: Adjusting hydraulic pressure