clamp hydraulic

AMP* Battery OperatedHydraulic Unit Assembly 122271–1

409–586911 SEP 95 Rev A

Customer Manual

409–5869

AMP Incorporated, Harrisburg, PA 17105 TECHNICAL ASSISTANCE CENTER 1–800–722–1111This document is Engineering controlled. It is subject to change. Contact TECHNICAL ASSISTANCE CENTER for latest revision.�Copyright 1995 by AMP Incorporated. All Rights Reserved.*Trademark LOC B

1 of 16

AMP* Battery OperatedHydraulic Unit Assembly 122271–1 11 SEP 95 Rev A

1. INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. Receiving Instructions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. Specifications 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. DESCRIPTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. Battery Charger 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. Battery 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3. Battery Operated Hydraulic Unit 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. SAFETY INFORMATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1. Battery Pack Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2. Battery Pack Removal 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3. Hydraulic Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4. Filling the Reservoir 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. Oil Level 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. Venting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3. Indicator Light 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. With Dump and Hold Valve on Unit 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. With Hand Control Pendant 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. MAINTENANCE 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1. Battery Charging 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. Battery Care 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3. Changing the Oil 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. ACCESSORIES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. Crimping Heads 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2. Crimping Dies 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3. Latch Pin Kits 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4. Hose Assemblies 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. RECEIVING INSPECTION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2. Removal of Crimping Head 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. OPERATING PROCEDURE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. PREVENTIVE MAINTENANCE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1. Cleaning 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2. Hydraulic Oil Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. REPLACEMENT AND REPAIR 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. BATTERY RECYCLING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. REVISION SUMMARY 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

409–5869Battery Operated Hydraulic Unit Assembly 122271–1

Rev A2 of 16

TECHNICAL ASSISTANCE CENTER

CALL TOLL FREE 1–800–722–1111(CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

1. Customer name 2. Customer address3. Person to contact (name, title, telephone number and extension)4. Person calling5. Machine or tool number (and serial number if applicable)6. Product part number (and serial number if applicable)7. Urgency of request8. Nature of problem9. Description of inoperative component(s)

AMP Incorporated offers the Technical Assistance Center as a means of providing technical assistance when required.

When contacting AMP Incorporated by telephone regarding service to a tool, 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 corrected in this manner.

When calling the Technical Assistance Center, be ready with the following information:

10. Additional information/comments that may be helpful

SAFETY PRECAUTIONS PREVENT INJURY

Safeguards are designed into AMP tools to protect operating personnel from most hazards during normal tool operation. However, as with most tooling, certain precautions must be taken by the operator and repairman to avoid personal injury or damage to the tool. Carefully observe the following safetyprecautions, and those throughout the text, before and during operation of the tool.

Do not exceed maximum hydraulic line pressure or tool damage may occur.

Never insert hands into any part of a hydraulic–powered tool without first shutting off the system pressure inthe line at the pump control panel or pendant. This will prevent injury in the event that switches or other con-trols are accidently activated. Never hold crimping dies of tool against hand or body when actuating tool. Toolcrimping head must be clear of all objects, or properly positioned on terminal post, when tool is actuated.

DANGER

INFORMATION REQUIRED WHEN CONTACTINGAMP INCORPORATED


Rev A 3 of 16

Figure 1

Battery OperatedHydraulic Unit 122271–2

Hand ControlPendant 217983–1

Battery Pack 217981–1

Battery Charger 217982–1

Quick–Coupler311471–1

1. INTRODUCTION

This customer manual covers AMP Battery Operated Hydraulic Unit Assembly 122271–1, the BatteryOperated Hydraulic Unit 122271–2, and accessories (see Figure 1). The unit, which combines the convenienceof a hand tool with the power of a larger machine, is used primarily for the application of AMP terminals andsplices on larger wire sizes 8 AWG through 1500 MCM (see Figure 9).

The customer manual provides operating and maintenance procedures, as well as general information, for theportable AMP Battery Operated Hydraulic Unit Assembly 122271–1. The customer is responsible formaintenance of the unit. Maintenance procedures include adjustments, operating procedures, minor repairs,and replacement of damaged or broken parts, battery recycling, as described in this manual.

For major repairs or production difficulties with the crimping head or pump unit, contact your AMPrepresentative; see Section 12, REPLACEMENT AND REPAIR.

The following instructions should be read carefully before operating the pump unit for the first time. Theperformance of the unit will depend largely upon information contained in this manual and operator training andskill. See Figure 9, which lists the crimping heads, instruction documentation, and products which may beapplied by this unit and the AMP Crimping Heads. Specifications for the AMP Battery Operated Hydraulic Unitare listed in Figure 2.


Rev A4 of 16

When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.

Denotes an imminent hazard which may result in moderate or severe injury.

Denotes a condition which may result in product or equipment damage.

Highlights special or important information.

Reasons for reissue are provided in Section 14, REVISION SUMMARY.

All measurements on this document are in metric units [with U.S. customary units in brackets].

1.1. Receiving Instructions

Visually inspect all components for shipping damage. If any shipping damage is found, notify carrier at once.Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or replacement costsresulting from damage in shipment.

1.2. Specifications

HYDRAULIC UNIT SPECIFICATIONS

Flow at 0 kPa [0 psi] 262 ml/minute [16 in3/minute]

Flow at 56539 kPa [8200 psi] 164 ml/minute [10 in3/minute]

Usable Oil Capacity 662 ml [38 in3]

Voltage 24 Vdc

Weight 8.4 kg [18.5 lbs]

LED Status Flashing Low Battery

Steady On Fault

BATTERY CHARGER SPECIFICATIONS

Voltage 100, 120, 220, 240 Vac

Frequency of Operation 50/60 Hz

Temperature Range 0� – 50� C [32� – 155�F]

Figure 2

2. DESCRIPTION

2.1. Battery Charger

The battery charger fully charges the battery pack in approximately one hour. Because the charger monitorsthe charge on the battery, the battery can be removed from the charger at any time and replaced withoutstarting the charging cycle from the beginning. When recharged in the battery charger, the battery will notexhibit a residual “memory effect,” and therefore does not require full discharging before recharging. Indicatorlights on the front panel show the status of the battery: READY, CHARGING, OVERHEAT, or DEFECTIVE. Ifthe battery is overheating, the charger shuts off, resuming the charging cycle once the battery has cooleddown. If the battery is defective, the charger shuts off.

Voltages are written on the surfaces of the fuse holder and, when located in the charging unit, can be seen through awindow on the charging unit. To select the appropriate voltage, remove the fuse holder and turn it until the desiredvoltage faces the window of the charging unit.

DANGER

CAUTION

NOTE

NOTE

NOTE


Rev A 5 of 16

2.2. Battery

The battery pack (217981–1) is a 24 Vdc, 1.7 ampere/hour, rechargeable Nickel–Cadmium battery, designedspecifically for use with the Battery Operated Hydraulic Unit.

This battery pack contains Nickel–Cadmium, a hazardous material. Do not puncture, disassemble, mutilate, orincinerate battery pack or cells.

To protect the life of the battery, use the battery pack only with the Battery Operated Unit 122271–1. Use only anapproved battery charger to protect the battery from overcharging.

2.3. Battery Operated Hydraulic Unit

The Battery Operated Hydraulic Unit is capable of producing up to 56539 kPa [8200 psi] of hydraulic pressure.This is a light–weight, highly portable power source for single–acting tools that crimp terminals and splices. Theunit comes with a shoulder strap hand control pendant, charger, and a rechargeable Nickel–Cadmium batterypack. Battery packs and chargers may also be ordered separately.

3. SAFETY INFORMATION

To avoid personal injury or property damage during system operation, read and follow all DANGER, CAUTION,and NOTE statements included with or attached to each product. Please read the following informational items:

AMP CANNOT be responsible for damage or injury resulting from unsafe use of product, lack of maintenance, orincorrect product and system application.

Contact AMP when in doubt as to application and safety precautions. See bottom of page 1.

To avoid personal injury, always wear proper personal protective gear when operating hydraulic equipment.

Make sure that all system components are protected from external sources of damage, such as excessive heat, flame,moving machine parts, sharp edges, and corrosive chemicals.

Carry the unit by the handle or the strap. Carrying or dragging the unit by the hose can damage the hose and/or theunit.

4. INSTALLATION

4.1. Battery Pack Installation

Slide the 217981–1 battery pack (A) into the pump battery compartment (B) until it latches into place. Figure 3shows the proper installation of the battery pack.

The battery pack can be inserted only in the proper direction. Do not force the battery into the compartment.

4.2. Battery Pack Removal

To remove the battery pack, press down on the battery release latch (C) (see Figure 3) and the battery willeject far enough to grasp and pull out.

Remove the battery pack from the unit when the unit is not in use. Storing the battery pack in the unit will causethe battery pack to discharge rapidly. To protect the life of the battery pack, store it in the charger.

DANGER

CAUTION

CAUTION

DANGER

DANGER

CAUTION

CAUTION

CAUTION


Rev A6 of 16

Figure 3

B

A

C

4.3. Hydraulic Connections (Figure 4)

Proceed as follows:

1. Connect a hose from the unit to the tool.

2. Hand–tighten quick–coupler (D) fully to ensure that all connections are tight and leak–free.

4.4. Filling the Reservoir (Figure 4)

Place unit on level surface. Unscrew the vent/fill cap (E) to expose the reservoir fill port. Add only high qualityhydraulic oil HF–101� or equivalent (see Figure 10). The reservoir is full when the oil level reaches the lip (F)in the neck of the fill port.

Add oil only when the tool is fully retracted, or the system will contain more oil than the reservoir can hold, causing oilto leak from vent/fill cap.

5. OPERATION

5.1. Oil Level

Check the oil level (see Figure 4) before operating the pump. If oil level is low, add oil until oil level reaches thelip (F) in the neck of the fill port. Use only high quality hydraulic oil HF–101 or equivalent.

5.2. Venting

Venting is provided automatically through the vent/fill cap, which also protects against reservoiroverpressurization.

� ENERPAC, a Unit of APPLIED POWER Inc.

CAUTION


Rev A 7 of 16

Figure 4

D

E

F

5.3. Indicator Light

Figure 5 shows the position of the indicator light (G). The light informs the operator when the battery isdepleted and when the motor has failed to operate.

When the battery needs recharging, the indicator light flashes, and will continue to flash until the battery hasbeen removed.

If the motor does not operate, the indicator fault light will go on and remain on as long as the PRESSUREbutton remains pressed. See Section 11, TROUBLESHOOTING, if the motor fails to operate.

5.4. With Dump and Hold Valve on Unit (Figure 5)

1. To advance the tool, press the PRESSURE button (1).

Figure 5

1 3

RELEASEPRESSURE

UNIT CONTROL PANEL

G


Rev A8 of 16

2. Release the PRESSURE button and the unit will hold the pressure.

3. To release system pressure and retract the tool, press the RELEASE button, (3), and hold until dieshave cleared the terminal to remove.

5.5. With Hand Control Pendant (Figure 6)

Figure 6 shows the operating positions of the pendant buttons. The pendant duplicates the operation of thebutton(s) located on the unit control panel.

The function switches located on the unit control panel and the hand control pendant are both operable at the sametime.

The indicator light (H) will glow when desired pressure has been reached.

Pressing the pendant PRESSURE button (1) activates the motor and advances the tool. Release thePRESSURE button and the unit will hold pressure. Pressing the pendant RELEASE button (2) releases systempressure and retracts the tool.

Figure 6

Hand ControlPendant

1 2

H

6. MAINTENANCE

6.1. Battery Charging

For indoor use only. Keep the battery charger and adaptor away from direct sunlight, moisture, and extremetemperatures.

The battery charger is for use with rechargeable Nickel–Cadmium batteries only.

The battery charger lights indicate the following:

Yellow––CHARGING Green––READY Orange––OVERHEAT Red––DEFECTIVE

Charge the battery by plugging in the charger and sliding the battery into the battery holder. The yellow lightflashes to indicate that the battery is charging.

When the green READY light goes on, the battery is fully charged.

If the orange OVERHEAT light goes on, do nothing. The charger automatically shuts off until the battery hascooled, and then resumes the charging cycle.

CAUTION

NOTE

CAUTION

CAUTION


Rev A 9 of 16

If the red DEFECTIVE light goes on, remove and re–insert the battery pack several times to ensure that thebattery is beyond recovery. If the yellow CHARGING light goes on, the battery may recover. If, through severalcharge and use cycles, the use period increases dramatically, the battery is functioning properly. If the useperiod does not increase dramatically, the battery is defective and should be disposed of properly. See Section13, BATTERY RECYCLING.

The battery will not overcharge if left in the charger indefinitely. Once the battery is fully charged, the charger entersthe maintenance mode, monitoring the battery and keeping it fully charged. During the maintenance mode the yellowlight will flash periodically as the charge “tops off” the charge on the battery. See Figure 7).

6.2. Battery Care (Figure 7)

Store the battery in the charger to keep it fully charged and ready for use. Shelf storage will result in slowdischarge of the battery. Store the battery and charger in a cool, dry environment. See NOTE above.

Storing the battery in the pump will cause the battery to discharge rapidly. If the battery is not removed from the pumpwhen the low battery indicator light turns on, the battery life will be shortened.

Figure 7

Battery Pack

Battery Charger

The battery pack is equipped with a fuse. If the fuse is blown, it must be replaced with a 30–ampereautomotive “mini” fuse (Littlefuse Part Number 297030 ).

DO NOT DISCARD! The battery pack contains hazardous material. Dispose of the battery pack in accordance withlocal recycling regulations. For more information on recycling the battery pack, see Section 13, BATTERYRECYCLING.

6.3. Changing the Oil

Change the oil in the unit once a year.

1. To drain oil, attach an open–ended hose to the quick–coupler (see Figure 5); depress PRESSUREbutton, actuating the motor and drain oil into a suitable container.

NOTE

CAUTION

NOTE


Rev A10 of 16

2. Unscrew and remove the vent/fill cap.

3. Add new hydraulic oil until oil level reaches the lip in the neck of the fill port.

4. Dispose of used oil properly.

7. ACCESSORIES

7.1. Crimping Heads

The Battery Operated Hydraulic Unit uses interchangeable crimping heads. Each crimping head usesinterchangeable crimping dies (with the exception of crimping head 69069, which has integral dies designed forthat particular head). The products to be crimped in each head are listed in the instructions accompanying thehead.

7.2. Crimping Dies

Each crimping head, except as noted in the preceding paragraph, uses interchangeable crimping dies designedfor that particular head. The instructions packaged with the dies give complete information.

7.3. Latch Pin Kits

Latch pin kits are available as accessories for the crimping heads as listed and shown in Figure 8.

7.4. Hose Assemblies

Hoses are sold separately as accessories and are available in different lengths; lengths and part numbers arelisted in Figure 8.

PivotPin

Coupling Pin Assembly

LatchPin

Crimping HeadCoupling

HoseAssembly

TypicalHead

RetainingRings

Screws

91–215

HEAD NUMBERLATCH PART NUMBER HOSE ASSEMBLY NUMBER

HEAD NUMBER KIT NUMBER PART NUMBER LENGTH MM [IN.]

69051 69709 314990–1 .61 [2]

69065 69709–2 314990–2 .91 [3]

69066 69709–3 314990–3 2.13 [7]

69067 69709–4 314990–4 14.57 [15]

Figure 8


Rev A 11 of 16

CRIMPING HEADS INSTRUCTIONSHEET

PRODUCTS CRIMPED

AMPLI–BOND*, PLASTI–GRIP*, Radiation Resistant, and Pre–Insulated AMPOWER Terminals and TERMINYL*,and COPALUM* Terminals and Splices

AMPOWER, SOLISTRAND*and STRATO–THERM*Terminals and Splices

AMPLI–BOND, PLASTI–GRIP, Radiation Resistant, Pre–Insulated AMPOWER and Pre–Insulated NylonHeavy Duty Terminals and TERMINYL, and COPALUM Sealed Terminals andSplices

SOLISTRAND Terminals andSplices, STRATO–THERM Terminals, Flag Terminals

SOLISTRAND Terminals and Splices

AMPOWER, COPALUM andSOLISTRAND Terminals andSplices, TERMI–FOIL*Terminals,AMPOWER Quick DisconnectTerminals and COPALUM InsulationPiercing Terminals and Splices, OpenBarrel Terminals

Self–ContainedDies

69069

AMPOWER, SOLISTRAND, Post–Insulated STRATO–THERM andCOPALUM Terminals and Splices

AMPOWER, SOLISTRAND, COPALUM and Post–Insulated, and Uninsulated STRATO–THERM Terminals and Splices, AMPOWERQuick Disconnect Terminals, SOLISTRAND Flag Terminals, COPALUM Insulated Piercing Terminals and Splices and TERMI–FOIL Terminals, Open BarrelTerminals, Stamped and Cast BatteryTerminals

AMPLI–BOND, PLASTI–GRIP, TERMINYL, Radiation Resistant, Pre–Insulated AMPOWER, Pre–InsulatedNylon Terminals, and Sealed COPALUM Terminals and Splices

69051 408–2450

58445–1 408–9598

69066 408–2453

69067 408–2454

69065 408–2452

408–1745

69082 408–2456

69097 408–2457

69099 408–2458

58422–1 408–9535

69051 SIZES 8 THRU 2

AWG

58445–1250 MCM

THRU 600 MCM

69065SIZES 8

THRU 4/0 AWG

69066SIZES 8

THRU 4/0 AWG

69067SIZES 8

THRU 4/0 AWG

68073–2SIZE 1250 MCMTHRU 1500 MCM

69097SIZES 8

THRU 1/0 AWG

690824/0 AWG

THRU 1000 MCM

69099SIZES 12–10 AWG

THRU 350 MCM

58422–1SIZES 8

THRU 4/0 AWG 90–40

68073–2 408–2449 AMPOWER* Terminals and Splices

69069SIZES 8

THRU 2 AWG(Self–Contained

Dies)

CRIMPINGHEAD NO.

Figure 9


Rev A12 of 16

8. RECEIVING INSPECTION

8.1. Installation

1. Remove unit from shipping carton.

The unit is a precision–built pump. ANY foreign particles entering the hydraulic fluid will damage polished surfaces,resulting in a loss in performance. It is important that the area around the reservoir filler cap and all threaded fittings becleaned before filling and assembly.

2. Thoroughly clean coupling areas of the hose and crimping head.

3. Remove protective dust caps from couplers, then assemble:

a. hydraulic hose quick–coupler to pump unit;

b. crimping head to hydraulic hose;

c. install crimping dies in crimping head (see instruction sheet packaged with dies for installation procedure).

Avoid personal injury: remove battery pack before changing dies.

8.2. Removal of Crimping Head

Unmating the quick–couplers facilitates removal of the crimping head; hold RELEASE button to ensure allpressure is removed from hose; then, unscrew collar on coupler.

9. OPERATING PROCEDURE

1. Advance ram partially by depressing PRESSURE button momentarily.

2. With dies partially closed, place terminal or splice in dies.

3. Once again, depress PRESSURE button to advance dies just enough to retain terminal or splice. Thedies will maintain a “hold” position long enough to allow the operator to insert wire(s) into a terminal orsplice before completing the crimping cycling.

If the PRESSURE button is depressed for too long, the dies will advance fully and crimp the wire barrel of the terminalor splice before wire(s) can be inserted.

If it is necessary to retract dies without completing crimp cycle, depress RELEASE button.

4. Insert stripped wire to proper insertion depth or wire stop in terminal or splice.

When crimping large wire splices: if possible, insert stripped wire into both ends of splice so that they butt against wirestops in middle of splice. If first crimp is made without conductors in both ends, the second conductor may be moredifficult to insert due to partial deformation of the splice. Rectangular conductors should be inserted so that crimpingpressure is applied to the flat side of the conductors.

5. Depress PRESSURE button until unit completes cycle and motor stops.

6. Depress RELEASE button to retract dies and then remove crimped terminal or splice.

10. PREVENTIVE MAINTENANCE

It is important that a preventive maintenance program be established and that maintenance be performed atregular intervals to ensure efficient, dependable performance of the unit. The preventive maintenance programincludes cleaning, visual inspection, checking release/kickoff pressure, and tightening of all external screwsand electrical connectors.

CAUTION

DANGER

NOTE

CAUTION

NOTE


Rev A 13 of 16

10.1. Cleaning

Clean breather hole in hydraulic oil vent/fill cap frequently, including the area surrounding the vent/fill cap.Perform an overall visual inspection of the entire unit at least once a month.

1. Check hydraulic oil level.

2. Inspect hoses for damage.

3. Check hydraulic release pressure.

10.2. Hydraulic Oil Specifications

If additional oil is required, it is essential that the proper grade of high–quality oil be used. Specifications andexamples of high–grade hydraulic oil for use in the unit are shown in Figure 10.

SPECIFICATIONS for HF–101 or EQUIVALENT

Viscosity Index 100/minute.

Viscosity at 99�C [210�F] 42/45 S.U.S. (Saybolt Universal Seconds)

Viscosity at 38�C [100�F] 150/165 S.U.S. (Saybolt Universal Seconds)

Viscosity at –17.8�C [0�F] Less Than 12,000 S.U.S.

API Gravity 31.0/33.0

Flash Point, C.O.C. (Cleveland Open Cup) 204�C [400�F]

Pour Point –32�C [–25�F]

Aniline Point 99 to 104�C [210 to 220�F]

Paraffinic Base Color Blue

Figure 10


Rev A14 of 16

11.TROUBLESHOOTING

The following information is intended as an aid in determining if a problem exists. Do NOT disassemble thepump. For repair service, return the unit to AMP Incorporated; see Section 12, REPLACEMENT AND REPAIR.

PROBLEM POSSIBLE CAUSE SOLUTION

Tool does not advance,advances slowly or

Oil level in pump reservoir is low. Add oil per Paragraph 4.4.advances slowly, oradvances unevenly. Release valve open. Close the release valve.

Loose hydraulic coupler. Check that all couplers are fully tightened.

Air trapped in system. Remove air by holding the unit higher than the tool and cycling itseveral times without building pressure.

Cylinder plunger binding. Check that all connections are tight and leak–free.

Tool advances, but does nothold pressure

Leaking connection. Check that all connections are tight and leak–free.hold pressure.

Leaking seals. Locate leak(s) and have equipment serviced by a qualified hydraulic technician.

Internal leakage in pump. Have unit serviced by a qualified hydraulic technician.

Tool does not retract,retracts part way or retracts

Release valve closed. Open release valve.retracts part way, or retractsmore slowly than normal. Pump reservoir is over filled. Drain oil level to lip in reservoir neck .

Loose hydraulic coupler. Check that all couplers are fully tightened.

Air trapped in system. Remove air by holding the unit higher than the tool and cyclingseveral times without building pressure.

Hose ID too small. Use a hydraulic hose with a larger diameter.

Crimp head retraction springbroken or other cylinder damage.

Return crimp head to AMP, see Section 12, REPLACEMENT AND REPAIR.

Motor fails to operate,Red light “on ”

Internal thermal switch is open. Wait approximately 20 minutes for the motor to cool. Red light “on.”

Break in the wiring. Have the unit serviced by a qualified hydraulic technician.

Failure of the motor relay. Have the unit serviced by a qualified hydraulic technician.

12. REPLACEMENT AND REPAIR

It may be necessary to return the unit to AMP Incorporated for repairs. Ship the unit (secured in an appropriateshipping crate or container) to:

CUSTOMER REPAIR (01–12)AMP INCORPORATED1523 NORTH 4TH STREETHARRISBURG, PA 17102–1604

Include a written description of the problem and what efforts were made to correct it before shipping the unit toAMP for repair.

Before electing to ship the unit to AMP for repair, it is advisable to contact the AMP Technical Assistance Center; seebottom of page 1.

NOTE

Ni–Cd


Rev A 15 of 16

13. BATTERY RECYCLINGThe battery pack contains Nickel–Cadmium, a hazardous material. The battery pack must be recycled.

Send used batteries to:

SANYO ENERGY (U.S.A.) CORPORATION2001 SANYO AVENUESAN DIEGO, CA 92173

When shipping used batteries:

1. Store the battery for 90 days to be sure it is fully discharged.

NEVER short the terminals of the battery pack to discharge it.

2. Choose a box size with minimal empty spaces to reduce the possibility of contents shifting.

Do not fill spaces in the package with paper or flammable material.

3. Seal box with packing tape.

4. Use an approved carrier and label the box: “Used Nickel–Cadmium Battery(s) for Recycling.”

You MUST use a Bill of Lading and include all information requested in the Bill, or Sanyo Energy Corporation mayreturn the shipment to you at your expense. The sample Bill of Lading, shown in Figure 11, may be used or copied.

Figure 11

Bill of Lading

Date of Transfer:

Shipper (from):

Name

Address

Phone number

Shipper Signature

Consignee Signature

Description of Contents: Waste Nickel Cadmium Battery(s) lbs.

Date

Date

Consignee (to):

SANYO Energy (U.S.A.) Corp.2001 Sanyo AvenueSan Diego, CA 92173(619) 661–6620

Carrier (via):

DANGER

CAUTION

NOTE


Rev A16 of 16

14. REVISION SUMMARY

This manual was revised according to EC 015–3395–95.

� Battery charger voltage, frequency, and temperature range specifications were added to Figure 2.� Note was added in Paragraph 2.1 describing voltage selection.� Changed Hose Assembly Part Numbers in Figure 8

From: To:59909–3 314990–159909–7 314990–2

1–59909–5 314990–32–59909–1 314990–4

� Deleted TERMALUM, COPALUM Sealed, and Inhibitor Filled COPALUM from Figure 9.

NOTES:

clamp hydraulic

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