Tyco Electronics 2119010- 1 Reference guide

409--10096
Customer Manual
1of 9
LOC B
E2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
27 AUG 09 Rev A
Air- Powered Hydraulic
Pump 2119010- 1
READ THIS FIRST ! 2.........................
SAFETY PRECAUTIONS
1. INTRODUCTION 3...................................................
2. SAFETY PRECAUTIONS 4.............................................
3. OPERATING PRECAUTIONS FOR THE PUMP 4.............................
4. PREPARATION AND SETUP 5..........................................
4.1. Hydraulic Connections 5...........................................
4.2. Hand Controller Installation 5........................................
4.3. Foot Controller Installation 5.........................................
4.4. Air Supply Hook--Up 6.............................................
4.5. Venting the Reservoir 6............................................
5. CONTROLLING THE PUMP 6...........................................
5.1. Priming the Pump Unit 7...........................................
5.2. Operating the Pump 7.............................................
5.3. Crimping Procedure 7.............................................
6. MAINTENANCE AND INSPECTION 7.....................................
6.1. Lubrication (For Hand/Foot, Manual Valve, and Remote Control Operated Pumps) 7
6.2. Bleeding Air from the System 7.......................................
6.3. Inspecting the Hydraulic Fluid Level 8..................................
6.4 Draining and Flushing the Reservoir 8..................................
6.5 Refilling the Reservoir 8............................................
6.6 Periodic Cleaning 8...............................................
7. TROUBLESHOOTING 9...............................................
8. REPAIR/REPLACEMENT 9.............................................
9. REVISION SUMMARY 9...............................................

409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A2 of 9 Tyco Electronics Corporation
SAFETY PRECAUTIONS AVOID INJURY
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:
DALWAYS wear appropriate ear protection.
DALWAYS wear approved eye protection when operating powered equipment.
DALWAYS keep guard(s) in place during normal operation.
DALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
DALWAYS turn off the main power switch and disconnect electrical cord from the power source when
performing maintenance on the equipment.
DNEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
DNEVER insert hands into installed application equipment.
DNEVER alter, modify, or misuse the application equipment.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1 - 800 - 722 - 1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance 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 TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance 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 Tooling Assistance Center, be ready with the following information:
01. Customer name
02. Customer address
03. Person to contact (name, title, telephone number, and extension)
04. Person calling
05. Equipment number (and serial number if applicable)
06. Product part number (and serial number if applicable)
07. Urgency of request
08. Nature of problem
09. Description of inoperative component(s)
10. Additional information/comments that may be helpful
DANGER

409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A 3 of 9Tyco Electronics Corporation
Figure 1
Pump Body
Hand Controller
Foot Controller
Hydraulic Coupler
Reservoir
Pressure Gage
1. INTRODUCTION
Air--Powered Hydraulic Pump 2119010--1 is a portable, air--powered, hydraulic pump used to power hydraulic
crimping heads.
The pump comes with a male hydraulic coupler and a hydraulic pressure gage. The hand or foot controllers are
sold separately. Hand controller 2119011--1 or foot controller 2119012--1 is required to operate the pump. See
Figure 1.
Dimensions in this document are in metric units [with U.S. customary dimensions in brackets].
NOTE
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409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A4 of 9 Tyco Electronics Corporation
2. SAFETY PRECAUTIONS
General Operation
SAll DANGER statements must be carefully observed to help prevent personal injury.
SBefore operating the pump, all hose connections must be tightened with the proper tools. Do not over-
tighten. Connections should only be tightened securely and leak--free. Overtightening can cause
premature thread failure or high pressure fittings to split at pressures lower than their rated capacities.
SShould a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off the pump
and release all pressure. Never attempt to grasp a leaking pressurized hose with your hands. The force
of escaping hydraulic fluid could cause serious injury.
SDo not subject the hose to potential hazard such as fire, sharp surfaces, extreme heat or cold, or heavy
impact. Do not allow the hose to be altered or kink, twist, curl, crush, cut, or bend so tightly that the fluid
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.
SDo not use the hose to move attached equipment. Stress can damage hose and possibly cause person-
al injury.
SHose material and coupler seals must be compatible with the hydraulic fluid used. Hoses also must not
come in contact with corrosive materials such as creosote--impregnated objects and some paints. Con-
sult the manufacturer before painting a hose. Hose deterioration due to corrosive materials can result in
personal injury. Never paint the couplers.
SInspect machine for wear, damage, and correct function before each use. Do not use machinery that is
not in proper working order, but repair or replace it as necessary.
SReplace worn or damaged safety decals.
SDo not modify the product.
SUse only components with the same pressure rating when assembling a system or machine.
Pump
SDo not exceed the hydraulic pressure rating noted on the pump data plate or tamper with the internal
high pressure relief valve. Creating pressure beyond the rated pressure can result in personal injury.
SBefore replenishing the fluid level, retract the system to prevent overfilling the pump reservoir. An overfill
can cause personal injury due to excess reservoir pressure created when cylinders are retracted.
Air Supply
SShut off and disconnect the air supply when the pump is not in use or before breaking any connections
in the system.
3. OPERATING PRECAUTIONS FOR THE PUMP
1. When connecting the coupler, be sure that no foreign objects are attached. If the coupler has become
dirty, clean it carefully before connecting it. Engaging the coupler when foreign objects are present will
damage the seals and lead to oil leakage from the connection.
2. Make sure that the coupler is securely connected. If the unit is pressurized while the coupler is not
properly connected, there will be damage to the seals or the crimp head.
3. Although a flexible hydraulic hose is used, do not bend it while pressure is being applied, or subject
the hose to shocks from metal objects. Either of these will shorten the working life of the hose and may
result in the hose bursting.
4. Never move the pump by pulling on the hydraulic hose or the remote control cords.
5. To ensure smooth operation of the pump, always use the pump after it has been stored for at least
one hour at 10°Cto25°C. If the pump is stored for an extended period below --5°C, viscosity of the oil
increases.
DANGER

409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A 5 of 9Tyco Electronics Corporation
6. Check the hydraulic oil regularly. Replenish the oil then the level becomes low. Use the appropriate
hydraulic oil type.
7. The pump is a precision device and should not be dropped or subjected to shocks or other abuse.
4. PREPARATION AND SETUP
4.1. Hydraulic Connections
Clean all the areas around the fluid ports of the pump and cylinder. Inspect all threads and fittings for signs of
wear or damage and replace as needed. Clean all hose ends, couplers, and union ends. Remove the thread
protectors from the hydraulic fluid outlets. Connect the hose assembly to the hydraulic fluid outlet and couple
the hose to the cylinder. See Figure 2.
Seal all external pipe connections with a high--grade, non--hardening thread sealant. TEFLONDtape may also be used
to seal hydraulic connections, provided only one layer of tape is used. Apply the tape carefully, two threads back, to
prevent it from being pinched by the coupler and broken off inside the system. Any loose pieces of tape could travel
through the system and obstruct the flow of fluid or cause jamming of precision--fit parts.
1. Identify each hose at the rear of the controller by the number engraved at the rear of the controller.
4.2. Hand Controller Installation (See Figure 2)
2. Insert each hose into the port with a corresponding engraved number at the rear of the pump.
4.3. Foot Controller Installation (See Figure 2)
1. Identify each hose by the number on the label at the end of each hose length.
2. Insert each hose into the port with a corresponding engraved number at the rear of the pump.
Figure 2
Rear of Pump Rear of Hand Controller
Rear of Foot Controller
DTrademark of E.I. DuPont de Nemours and Company
NOTE
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409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A6 of 9 Tyco Electronics Corporation
4.4. Air Supply Hook- Up
Remove the thread protector from the air inlet of the pump. Select and install the threaded fittings that are
compatible with your air supply fittings. The air supply should be 20 CFM (0.57 M3/min.) and 100 PSI (7 BAR)
at the pump to obtain the rated hydraulic pressure. Air pressure should be regulated between 98 and 102 PSI
for 10,000 PSI hydraulic equipment, and 80 and 84 PSI for 8,200 PSI hydraulic equipment. This pump has an
air pressure to hydraulic pressure ratio of 1:100.
Secure your pump fitting to the air supply. See Figure 3.
If improperly used, pressurized equipment can be potentially hazardous. Therefore:
DHydraulic connections must be securely fastened before building pressure in the system.
DRelease all system pressure before loosening any hydraulic connection in the system.
Figure 3
Remote Hand Control (Ref)
Hydraulic Hose
Coupler
Hydraulic Head (Ref)
Three--Strand Air Hose
Air Hose
Coupler
Lubricator
Filter
Tee Adapter
Male Fitting
Air Hose
Air Filter
Inline Air Pressure
Gage
4.5. Venting the Reservoir
To improve hydraulic fluid delivery and increase useable hydraulic fluid capacity, remove shipping plug and
install filler/vent cap before using the pump.
5. CONTROLLING THE PUMP
PICTOGRAM DEFINITIONS
Activating the pump with the switch end marked with this pictogram,
the flow of fluid is directed out of the reservoir.
Activating the pump with the switch end marked with this pictogram,
the flow of fluid is directed back to the reservoir.
DANGER

409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A 7 of 9Tyco Electronics Corporation
5.1. Priming the Pump Unit
Under certain circumstances, it may be necessary to prime the pump unit. To accomplish this, perform the
following procedure:
Depress the (or advance) and (or retract) switches on the hand or foot controller simultaneously
and allow the pump to cycle for approximately 15 seconds. Release both switches and then depress the
(or advance) switch once more. If the cylinder extends or pressure builds, the pump has been successfully
primed. If the pump does not respond, repeat the procedure. If pump still does not respond, tip pump
upside--down and repeat the procedure.
5.2. Operating the Pump
1. To advance the ram, depress the switch on the hand or foot controller marked (or advance).
2. To hold the ram in position, release the (or advance) switch.
3. To retract the cylinder, depress the switch on the hand or foot controller marked (or retract). The
ram will continue to retract for as long as the switch is depressed.
5.3. Crimping Procedure
1. Strip the wire(s) to be crimped according to the instructions included with the crimping head or die
assembly.
2. Place the terminal or splice in the crimping dies according to the instructions included with the
crimping head or die assembly.
3. Depress the switch marked (or advance) to advance the ram just enough to hold the terminal or
splice in place, then release the switch. Care should be taken to not deform the terminal or splice.
4. Insert the stripped wire(s) into the wire barrel of the terminal or splice.
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.
5. Depress the (or advance) switch until the hydraulic pressure gage displays the desired crimping
pressure.
The proper crimping pressure range for 10,000 PSI hydraulic equipment is 9,800 PSI to 10,200 PSI. The proper
crimping pressure range for 8,200 PSI hydraulic equipment is 8,000 to 8,400 PSI.
6. After the pump reaches the desired pressure, depress the (or retract) switch to retract the ram
and remove the crimped terminal or splice from the dies.
6. MAINTENANCE AND INSPECTION
DAny repair or servicing that requires dismantling the pump must be performed in a dirt--free environment by a
qualified technician.
DDispose of machine and fluids properly.
6.1. Lubrication (For Hand/Foot, Manual Valve, and Remote Control Operated Pumps)
If the pump is operated on a continuous duty cycle for extended periods, the manufacturer recommends
installing an automatic air line oiler in the air inlet line as close to the pumping unit as possible. Set the unit to
feed approximately one drop of oil per minute into the system. Use SAE grade oil, 5W to 30W.
6.2. Bleeding Air from the System
During the first moments of operation or after prolonged use, a significant amount of air may accumulate within
the hydraulic system. This entrapped air may cause the crimping head to respond slowly or behave in an
NOTE
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NOTE
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409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A8 of 9 Tyco Electronics Corporation
unstable manner. To remove the air, run the system through several cycles (extending and retracting the
crimping head) free of any load. The crimping head must be at lower level than the pump to allow air to be
released through the pump reservoir.
6.3. Inspecting the Hydraulic Fluid Level
Check the fluid level in the reservoir after every ten hours of use. Drain and replenish the reservoir with
approved hydraulic fluid after 300 hours of use approximately.
The fluid level should be 12.7 mm [.500 in.] from the filler/vent cap with all cylinders retracted.
6.4. Draining and Flushing the Reservoir
Wipe the pump exterior completely clean before attempting this procedure.
1. Remove the 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. Drain the reservoir of all fluid and refill half full with clean hydraulic fluid. Rinse the filter clean.
3. Place the pump assembly back onto the reservoir, and secure with two of the machine screws
assembled in opposite corners of the housing.
4. Run the unit for several minutes. Use the same method described in Paragraph 5.1 (Priming the
Pump Unit).
5. Drain and clean the reservoir once more.
6. Refill the reservoir with approved hydraulic fluid and replace the pump assembly (with gasket) on the
reservoir and install the screws. Torque the screws as follows: for 1.7 L [105 cubic in.] reservoirs, torque
to 2.8--3.4 NDm [25--30 in.--lbs.]; and for 7.6 L [2 gal.] reservoirs, torque to 4.0--5.0 NDm [35--45 in.--lbs.].
Drain and clean the other hydraulic system components (hoses, cylinders, etc.) before reconnecting them to the pump.
This will prevent contaminated fluid from entering the pump again.
6.5. Refilling the Reservoir
If additional fluid must be added to the reservoir, use only approved hydraulic fluid (215 SSU @ 38°C [100°F]).
Clean the entire area around the filler plug before adding fluid to the reservoir. Remove the filler plug, and
insert a clean funnel with filter. The crimping head must be fully retracted and the air supply disconnected when
adding the fluid to the reservoir.
6.6. Periodic Cleaning
The greatest single cause of failure in hydraulic pumps is dirt. Keep the pump and attached crimping head clean to
prevent foreign matter from entering the system.
A routine should be established to keep the pump as free from dirt as possible. All unused couplers must be
sealed with thread protectors. All hose connections must be free of grit and grime. Any crimping head hooked
up to the pump should also be kept clean. Use only approved hydraulic fluid in the unit and change as
recommended (every 300 hours).
NOTE
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NOTE
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409- 10096
Air- Powered Hydraulic Pump 2119010- 1
Rev A 9 of 9Tyco Electronics Corporation
7. TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
1. Low fluid level. 1. Add fluid as instructed in Preventive
Maintenance section.
Pump reciprocates but no fluid delivery
(crimping head will not extend) 2. Pump not primed. 2. Prime pump as instructed in Operation
section.
3. Fluid intake filter contaminated. 3. Remove reservoir and clean intake filter
and reinstall.
1. Inadequate air supply. 1. a. Should be 20 CFM
(0.57 M3/min.) minimum.
a. Check air input supply. b. Clean and reassemble.
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b. Contamination, check air side of
pump (plugged air inlet screen).
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slowly)2. Hydraulic failure. 2. a. Remove reservoir and clean
intake filter and reinstall.
a. Check the fluid inlet filter for
contamination.
b. Bleed the system as described
in the Preventative Maintenance
section.
b. Air in hydraulic system.
Pum
p
will not build to maximum
p
ressure
1. Check the air supply. 1. Air supply should be set to produce the
desired hydraulic pressure.
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e
(no visible leakage) 2. Pressure regulator improperly adjusted
(if so equipped).
2. Adjust according to instructions in
Operating Section.
Pump builds pressure but will not hold
system pressure
1. Check the hydraulic connections and other
system components for leakage, including
3--way valve (is so equipped).
1. Refit or repair as needed.
Pum
p
will continue to run slowl
y
even
1. Output pressure equal to or higher than
relief valve setting. 1. Normal operation.
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after desired pressure is reached 2. Defective 3--way valve or other
components leaking. 2. Repair or replace.
Excessive oil spray from muffler 1. Air lubricator is set too rich
(if so equipped). 1. Set at one drop per minute.
8. REPAIR/REPLACEMENT
If there are major problems with the pump, it should be returned to Tyco Electronics at:
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
Tools may also be returned to Tyco Electronics for evaluation and repair. For tool repair service, contact a Tyco
Electronics Representative at 1--800--526--5136.
9. REVISION SUMMARY
SInitial release of document