1-2031400-1

Customer Manual 409-10095 07 AUG 15 Rev H ORIGINAL INSTRUCTIONS Electro-Hydraulic Hand Tool Kit 2031400-[ ] SAFETY PRECAUTIONS — READ THIS FIRST! ..................................................................... 2 SAFETY PRECAUTIONS — AVOID INJURY — READ THIS FIRST! ...................................... 3 1. INTRODUCTION .................................................................................................................. 6 2. SPECIFICATIONS ................................................................................................................ 7 3. RECEIVING/INSPECTION ................................................................................................... 7 4. INSTALLATION/REMOVAL OF CRIMP TOOLING ............................................................ 8 4.1. Installation/Removal of CERTI-CRIMP II* Tool Adapters ............................................ 8 4.2. Installation/ Removal of Crimping Head ...................................................................... 8 4.3. Battery or AC Adapter Installation and Removal ......................................................... 9 5. OPERATION ........................................................................................................................ 9 6. PRESSURE RELEASE/RESET TOOL .............................................................................. 10 7. PREVENTIVE MAINTENANCE ......................................................................................... 10 7.1. Daily Maintenance ..................................................................................................... 11 7.2. Yearly Maintenance ................................................................................................... 11 7.3. General Notes ........................................................................................................... 11 8. RETURN/REPAIR .............................................................................................................. 11 9. TROUBLESHOOTING ....................................................................................................... 12 10. REVISION SUMMARY ....................................................................................................... 12 © 2015 TE Connectivity family of companies All Rights Reserved *Trademark 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. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. 1 of 12 409-10095 SAFETY PRECAUTIONS — READ THIS FIRST! IMPORTANT SAFETY INFORMATION NOTE Keep all decals clean and legible, and replace them when necessary. DANGER ELECTRIC SHOCK HAZARD This tool is not insulated. When using this unit near energized electrical lines, use proper personal protective equipment. Failure to observe this warning could result in severe injury or death. DANGER SKIN INJECTION HAZARD Do not use hands to check for oil leaks. Highly pressurized oil will puncture the skin causing serious injury, gangrene, or death. If injured, seek medical help immediately to remove the oil. DANGER FIRE HAZARD Do not use solvents or flammable liquids to clean the crimping tool. Solvents or flammable liquids could ignite and cause serious injury or property damage. Failure to heed these warnings could result in severe injury from harmful fumes or burns from flying debris. DANGER FIRE HAZARD Do not dispose of batteries in a fire. They will vent fumes and will explode. Instead, dispose of batteries in an environmentally responsible manner or send the battery back to TE. DANGER Inspect the tool and jaws/dies before each use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike nearby personnel. Failure to observe this warning could result in severe injury or death. Rev H CAUTION — Do not place the tool in a vise. The crimping tool is designed for hand-held operation. — Protect the crimping tool from rain and moisture. Water will damage the crimping tool and battery. Failure to observe these precautions may result in injury or property damage. CAUTION — Do not allow anything to contact the battery terminals. — Do not immerse the batteries in liquid. Liquid may create a short circuit and damage the battery. If the batteries are immersed, contact your service center for proper handling. — Do not place the battery into a pocket, tool pouch, or tool box with conductive objects. Conductive objects may create a short circuit and damage the battery. — Do not place a battery on moist ground or grass. Moisture may create a short circuit and damage the battery. Failure to observe these precautions may result in injury or property damage. CAUTION — Do not store the battery at more than 60°C [140°F]. Damage to the battery can result. — Do not use another manufacturer’s charger. — Do not attempt to open the battery. It contains no user-serviceable parts. Failure to observe these precautions may result in injury or property damage. CAUTION — Do not perform any service or maintenance other than as described in this manual. Injury or damage to the tool may result. Failure to observe these precautions may result in injury or property damage. 2 of 12 409-10095 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. Observe lift point for equipment. Always wear appropriate ear protection while using equipment. Always disconnect air supply and then exhaust system air pressure before performing maintenance or repair on the equipment. Wear foot protection. Wear nitrile gloves. Moving parts can crush and cut. Always keep guard(s) in place during normal operation. Always insert power plug into a grounded receptacle to avoid electrical shock. Always disconnect the air and lockout the tool when not in use or when head or tool holder is detached. Use caution when working with this 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. Electrical shock hazard. Observe main electric on/off switch. Always turn off the main power switch and disconnect the electrical cord from the power source when performing repair or maintenance on the equipment. Ensure that guards are in place and secure to equipment. Do not operate the equipment without guards in place. Never enter the electrical enclosure immediately after turning off the machine power switch and disconnecting the electrical cord from the power source. High residual voltages may be present in the electrical enclosure. Read the warning label on the electrical enclosure lid before entering the enclosure. Never stare at the bright light used for machine lighting. Bright light can damage the eye. Never use the machine for other than what it is designed, which is crimping terminals to wire. Do not use the machine for crushing any items. : Rev H 3 of 12 409-10095 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 2. Customer address 3. Person to contact (name, title, telephone number, and extension) 4. Person calling 5. Equipment number (and serial number if applicable) 6. Product part number (and serial number if applicable) 7. Urgency of request 8. Nature of problem 9. Description of inoperative component(s) 10. Additional information/comments that may be helpful Rev H 4 of 12 409-10095 Power Unit Typical Crimping Head (Shown with SDE Die Set. Note that the Crimping Head is NOT Part of the Hand Tool Kit. Cylinder Assembly Battery The Kit Also Contains a Carrying Case and a Battery Charger. Carrying Case Battery Charger ELECTROHYDRAULIC HAND TOOL KIT BATTERY CHARGER (INCLUDED) OPTIONAL AC TO DC POWER ADAPTER BATTERY CHARGER AND OPTIONAL POWER ADAPTER VOLTAGE PLUG TYPE REGION OF USE 2031400-1 2031400-5 2063870-1 2063874-1 110 VAC NEMA 1-15 N. AMERICA 2-2031400-1 2-2031400-5 2063870-2 2063874-2 220 VAC CEE 7/17 EU 1-2031400-1 1-2031400-5 2063870-4 2063874-4 110 VAC JIS-C-8303 JAPAN 3-2031400-1 3-2031400-5 2063870-3 2063874-3 220 VAC BS-1363 UK 4-2031400-1 4-2031400-5 2063870-5 2063874-5 220 VAC AS/NZS 3112 AUS/CHINA 2031400-4 2280961-1 2063874-1 110 VAC NEMA 1-15 N. AMERICA Figure 1 Rev H 5 of 12 409-10095 1. INTRODUCTION The Electro-Hydraulic Hand Tool kit 2031400-[ ] consists of the Electro-Hydraulic Hand Tool, one rechargeable battery cartridge (2031440-[ ]), a battery charger (2031441-[ ]) and a carrying case. To use the tool without a battery, an optional AC to DC power adapter (2031443-[ ]) is available. These assemblies are listed in the table in Figure 1. The Electro-Hydraulic Hand Tool is designed to accept interchangeable head assemblies which accept interchangeable SDE die sets used for crimping various types of electrical wire connectors. Head assemblies and die sets are not included in this kit and must be ordered separately. NOTE The tool should ONLY be used by trained, competent operators. This manual contains NOTE, CAUTION, and DANGER, and WARNING statements. NOTE Highlights special or important information. CAUTION Denotes a condition which may result in product or equipment damage. DANGER “Dangers” and “Warnings” denote an imminent hazard which may result in moderate or severe injury. Refer to the 124 series document (124-1002) for General Power Tool Safety Warnings. NOTE Dimensions in these instruction are in millimeters [with inch equivalents provided in brackets.] Figures are for reference only and are not drawn to scale. For tooling assistance (or service information), call the PRODUCT INFORMATION number at: 1.800.522-6752. Rev H 6 of 12 409-10095 2. SPECIFICATIONS CRIMPING CAPACITIES PART NUMBER 2031400-1, -4, -11, -21, -31, -41 2031400-5, -15, -25, -35, -45 15.6 kN [3500 lb] Max 8.5 kN [1900 lb] Max Oil Pressure 276 bar [4000 psi] 247 bar [3600 psi] Max Crimping Time 4 Seconds Approx. 3 Seconds Approx. 250 Approx. 250 Approx. Rated Crimping Force Crimps per Charge CRIMPING TOOL Length† 240 mm [9.4 in.] 240 mm [9.4 in.] Width† 59 mm [2.3 in.] 59 mm [2.3 in.] Depth† 48 mm [1.9 in.] 48 mm [1.9 in.] Weight† 0.6 kg [1.4 lb] 0.6 kg [1.4 lb] Vibration†