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BI617075

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BUCYRUS R

Technical Manual

BI617075

AMP* Hydraulic Power Units 69120–1 and 69120–2

409–1950 20 MAY 92 Rev O

BI617075

CM 1950

AMP* HYDRAULIC POWER UNITS 69120–1 AND 69120–2

5–20–92

customer manual AMP INCORPORATED Harrisburg, PA 17105

This AMP controlled document is subject to change. For latest revision, contact Technical Publications. To obtain a copy of this document, internal customers mail Requisition Form (AMP 168) to Literature Distribution 84–13. External customers call the Customer Support Center at (717) 780–4444.

* Trademark of AMP Incorporated Copyright 1963, ‘65, ‘68, ‘71, ‘73, ‘74, ‘76, ‘79, ‘83, ‘90, ‘92 by AMP Incorporated. All International Rights Reserved.

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Prepared by Technical Publications, AMP Incorporated

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CM 1950

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Frontispiece.

CM 1950

Hydraulic Power Unit 69120–[ ]

90–38

iii

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DANGER SAFETY PRECAUTIONS PREVENT INJURY Safeguards are designed into AMP machines to protect operating personnel from most hazards during normal machine operation. However, as with most machinery, certain precautions must be taken by the operator and repairman.

Never insert hands into an installed machine/applicator, or any part of a machine that is operated by electricity or compressed air, without first pulling the machine power cable plug from the outlet receptacle and/or shutting off the compressed air at the line valve and disconnecting the air hose. This will prevent injury in the event that switches or other controls are accidentally activated.

A grounded electrical outlet should always be used to receive the plug on the machine power cable.

To improve clarity, photographs and drawings may not show machine/applicator guards. In some cases, it is impractical to show the variety of guards designed to meet specific safety requirements, as set forth in codes and standards adopted by customers and/or enforced in a given locale.

Though a guard may not be shown, and procedures may not reflect the need for its removal, the guard must be in place during normal operation of the machine/applicator.

CUSTOMER HOTLINE MACHINE/PRODUCT SERVICE CALL TOLL FREE 1 800 722–1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)

GENERAL MACHINE POLICY

D ALWAYS disconnect power cord plug before performing any maintenance on power unit.

D ALWAYS disconnect power cord plug before

INFORMATION REQUIRED WHEN CONTACTING FIELD ENGINEERING SERVICES AMP Field Engineering Services offers the Customer Hotline as a means of providing technical assistance when required.

maintenance procedure to ensure efficient, safe operation of the power unit.

When contacting AMP Field Engineering Services by telephone regarding service to a machine or 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.

D ALWAYS insert power cord plug into a

When calling the Customer Hotline, be ready with the following information:

changing dies.

D ALWAYS perform the monthly preventive

properly grounded receptacle supplying the voltage specified on the unit name plate.

D NEVER operate power unit without hose and crimping head attached.

D ALWAYS exercise caution while holding terminals, splices, or wire near crimping area.

D ALWAYS wear eye protection when operating powered machinery.

D BEFORE USING, ensure that all units are properly grounded.

iv

1. Customer name 2. Customer address 3. Person to contact (name, title, telephone number and extension) 4. Person calling 5. Machine or tool 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

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CONTENTS 1.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.

2.

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.1.

2.2.

2.3.

3.

Crimping Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Crimping Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Latch Pin Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.1.

3.2.

3.3.

4.

Filling Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

RECEIVING INSPECTION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.1.

4.2.

4.3.

Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal of the Crimping Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.

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

6.

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6.1.

6.2.

6.3.

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8.

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 8.1.

8.2.

8.3.

9.

Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjusting Electrical Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Low–Pressure Check Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

REPAIRS AND PARTS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 9.1.

9.2.

9.3.

9.4.

9.5.

9.6.

9.7.

9.8.

9.9.

Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Accumulator “O” Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Handle Control Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Foot Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Relay and Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Safety Relief Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Valve Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10. PARTS LISTS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 11. FACTORY REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 CM 1950

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ILLUSTRATIONS

Frontispiece

Hydraulic Power Unit 69120–[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

1–1.

Hydraulic Power Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2–1.

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2–2.

Crimping Head and Product Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2–3.

Latch Pin Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3–1.

Cutaway, Directional Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3–2.

Wiring Diagram for Unit Numbers 69120–1 and 69120–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3–3.

Wiring Diagram for Multidirectional Valve Assembly, Handle Controls, and Power Unit Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4–1.

Hydraulic Power Unit 69120–[ ] with Hose, Handle Control, and Crimping Heads and Dies (Foot Control Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5–1.

Handle Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5–2.

Foot Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8–1.

Pressure Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8–2.

Installing Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8–3.

Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8–4.

Low–Pressure Check Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

9–1.

Accumulator “O” Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9–2.

Handle Control Disassembly, Wiring, and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9–3.

Foot Control Disassembly and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

9–4.

Coil Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

10–1.

Assemblies, Accessories: Hydraulic Power Unit 69120–[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10–2.

Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

10–3.

Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10–4.

Pressure Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

10–5.

Solenoid Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

10–5A. Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 10–6.

Reservoir Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

10–7.

Handle Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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CM 1950

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1.

INTRODUCTION

This manual provides operating and maintenance procedures, as well as general information, for AMP Hydraulic Power Unit 69120–[ ]. The customer is responsible for maintenance of the unit. Maintenance procedures include adjustments, minor repairs, and replacement of damaged or broken parts as described in this manual.

For major repairs or production difficulties with the power unit, AMP Field Engineering assistance is available at a nominal fee. AMP Field Engineering may be contacted via:

CUSTOMER HOTLINE MACHINE/PRODUCT SERVICE CALL TOLL FREE 1 800 722–1111 (Continental United States and Puerto Rico Only) The following instructions should be read carefully before operating the power unit for the first time. The performance of the unit will depend largely upon information contained in this manual and operator training and skill. All power units, crimping heads, die assemblies and other accessories are carefully tested and adjusted before shipment to ensure their quality and integrity.

This manual covers AMP Hydraulic Power Units 69120–1 and 69120–2, and their accessories. The unit, which combines the convenience of a hand tool with the power of a larger machine, is used primarily for the application of AMP terminals and splices on larger wire sizes.

The power unit is, basically, a portable crimping unit which uses a handle or foot control to activate the pump. This type of operation provides a larger working radius than that of a bench unit and also allows accessibility to confined areas. Quick–disconnect couplers are used to assemble the hydraulic hose to the power unit and crimping head to form a complete crimping unit. A complete line of precision–engineered heads and matched die assemblies are available for the unit from AMP Incorporated. Refer to Section 2, ACCESSORIES, of this manual for general information regarding crimping heads and die assemblies.

Specifications for hydraulic power units are listed in Figure 1–1.

ELECTRICAL REQUIREMENTS

MOTOR

CURRENT DRAW (Max)

MAXIMUM PRESSURE OUTPUT

dBA at Idle & 8400 psi

OIL CAPACITY

115 Vac Only/60 Hz (69120–1 unit)

1 1/8 HP 50/60 Hz Single Phase 8400 RPM

27 amps

8400 psi

90/95{

2 Gallons

220/230 Vac Only, 50/60 Hz (69120–2 unit)

{ Noise level reading (dBA) measured at a 3 ft distance, all sides.

OIL DELIVERY (cu in./min at:) 100 1000 5000 8400 psi psi psi psi 650

80

70

DIMENSIONS

NET WEIGHT

11 1/2” L x 9 1/2” W x 18 1/4” H

65 lb (w. oil)

PRESSURE VS. VOLUME 800 700 600

55 OIL VOLUME (CU. IN./ MIN.)

500 400 300 200

PERFORMANCE CURVE FOR HYDRAULIC POWER UNIT 69120–[ ] INDICATING OIL DELIVERY AT RELATIVE PRESSURE LEVELS

100 0 500

1000

2000 3000 4000 5000 6000 7000 8000 9000

PRESSURE (P.S.I.)

Fig. 1–1.

CM 1950

Hydraulic Power Unit Specifications

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2.2. Crimping Dies Each crimping head uses interchangeable crimping die assemblies which have been specifically designed for that particular head (with the exception of crimping head 69069 which has self–contained dies).

An instruction sheet covering the dies is packaged with its respective die assembly.

2.3. Latch Pin Kits Latch pin kits are accessory items for the crimping heads, as listed and shown in Figure 2–3. Use of a latch pin kit eliminates the possibility of misplacing the standard latch pin furnished with the head.

TYPICAL HEAD RETAINING RINGS

HEAD NUMBER

LATCH PIN KIT NUMBER

69051 69065 69066 69067

69709 69709–2 69709–3 69709–4

PIVOT PIN

SCREWS

COUPLING ASSEMBLY

LATCH PIN

Fig. 2–3.

3.

Latch Pin Kits

90–41

DESCRIPTION

3.1. Physical Description The power unit 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 unit features a hydraulic fluid reservoir and pressure regulation and control devices for the pumps. A schematically detailed functional description is given in Paragraph 3.2.

3.2. Functional Description The motor and pump assembly supplies fluid under high pressure into the directional valve assembly. See Figure 3–1A. Fluid is also supplied from the motor and pump assembly under low pressure through low– pressure check valve “T”. When the low–pressure fluid holds the valve pin “S” closed, fluid under high pressure is supplied to the crimping head.

The low pressure fluid is directed to valve pin “S” by a combination of control functions. The low–pressure fluid is pumped through low pressure check valve “T” and accumulator “Y” into the energized solenoid section of the assembly. Valve “T” prevents the low–pressure fluid from returning to the system when high pressure is applied to valve pin “S”. Accumulator “Y” maintains sufficient hydraulic pressure against valve pin “S” in the event leakage occurs through poppet valve “W” and/or valve pin “S”.

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As long as the solenoid is energized, it holds poppet valve “W” in the position shown in Figure 3–1A; the low–pressure fluid holds valve pin “S” closed, causing a constant supply of high–pressure fluid to be applied to the crimping head. As pressure buildup in the head increases, piston “V” is activated and electrical contact is broken at pressure switch “U”. The pressure switch adjustment screw and locknut are set at the factory so that the pressure switch is activated at a pressure of 8,000 psi. When contact is broken at pressure switch “U”, the pump motor shuts off. The solenoid is de–energized and poppet valve “W”, aided by spring “Z” moves to the right. See Figure 3–1B. As poppet valve “W” moves to the right, low–pressure fluid is released and returned to the reservoir. High–pressure fluid, aided by spring “Z–1”, moves valve pin “S” to the left. The high–pressure fluid then returns to the reservoir through opened valve pin “S”.

Before the next cycle can be started, a RESET switch must be activated. This energizes the solenoid to return poppet valve “W” to the position shown in Figure 3–1A.

3.3. Wiring Diagrams Refer to the following Figures for the electrical wiring of the power unit models and accessories covered in this manual: — Power Units 69120–1 and 69120–2 — Multidirectional Valve Assembly (with handle control and power unit socket) — Handle Control — Foot Control

CM 1950

Figure 3–2 Figure 3–3 Figure 9–2 Figure 9–3

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BI617075

SOLENOID (Energized)

A

POPPET VALVE “W”

SPRING “Z–1” PRESSURE SWITCH “U”

SPRING “Z”

VALVE PIN “S”

ACCUMULATOR “Y” PISTON “V”

TO RESERVOIR

HIGH–PRESSURE LINE TO CRIMPING HEAD LOW–PRESSURE CHECK VALVE “T”

B

SPRING “Z”

HYDRAULIC LINES FROM MOTOR AND PUMP ASSEMBLY

LOW–PRESSURE LINE SOLENOID (De–energized) POPPET VALVE “W”

SPRING “Z–1” PRESSURE SWITCH “U”

NOTE: THIS ILLUSTRATION IS NOT COMPLETE IN DETAIL. ONLY THOSE DETAILS PERTINENT TO A FUNCTIONAL DESCRIPTION ARE SHOWN. VALVE PIN “S”

ACCUMULATOR “Y” PISTON “V” TO RESERVOIR HIGH–PRESSURE LINE TO CRIMPING HEAD LOW–PRESSURE CHECK VALVE “T”

Fig. 3–1 (A and B).

6

LOW–PRESSURE LINE

Cutaway, Directional Valve Assembly

HYDRAULIC LINES FROM MOTOR AND PUMP ASSEMBLY

90–42, 90–43

CM 1950

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4.

RECEIVING INSPECTION AND INSTALLATION (Figure 4–1)

4.1. Receiving Inspection The hydraulic power unit is thoroughly inspected during and after assembly. A final series of inspections is made to ensure proper functioning of the unit before packaging and shipping. However, damage may occur during shipment. Therefore, while unpacking the unit by removing outer bands from carton or crate and lifting off outer box, CAREFULLY inspect complete machine for damage. If damage is evident, file a claim against the carrier and notify AMP Incorporated immediately.

PRESSURE RELEASE BUTTON

PILOT LAMP

I.D. PLATE SPECIFICATION PLATE

HYDRAULIC FLUID RESERVOIR FILLER CAP ON CORNER OF UNIT BEHIND MOTOR

ELECTRICAL CONTROL BOX

PRESSURE SWITCH

POWER SUPPLY CORD

DIRECTIONAL VALVE HANDLE CONTROL CORD PLUG

MOLDED PLUG

UNIVERSAL MOTOR COUPLER INTERCHANGEABLE CRIMPING HEAD

INTERCHANGEABLE DIES

CASTERS DUST COVER HANDLE CONTROL CORD

COUPLER

DUST COVER

HYDRAULIC HOSE HANDLE CONTROL

DUST CAP

Fig. 4–1. Hydraulic Power Unit 69120–[ ] with Hose, Handle Control, and Crimping Heads and Dies (Foot Control Not Shown)

8

90–46, cad

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BI617075

4.2. Installation 1.

Remove unit from shipping pallet (plywood).

2. Insert four casters (shipped with unit) into sockets on bottom corners of unit. Casters are required only when unit is used in portable applications.

3. Remove reservoir filler cap and insert a clean, filter–equipped funnel into filler hole. Fill reservoir with two gallons of hydraulic fluid (shipped with the unit) to a level of not more than 1 in. from top of filler hole. Replace cap and ensure that breather hole in cap is open. Whenever additional fluid is required, refer to Paragraph 6.3., Hydraulic Fluid Specifications.

CAUTION

The power 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 be cleaned before filling and assembly.

4.

Thoroughly clean coupling areas of handle or foot control, hose, and crimping head.

5.

Remove protective dust caps from couplers, then assemble: (a) (b) (c)

DANGER

hydraulic hose quick–coupler and handle or foot control electrical connections to power unit crimping head to hydraulic hose. install crimping dies in crimping head (see instruction sheet packaged with dies for installation procedure).

Avoid personal injury: disconnect power cord plug before changing dies.

4.3. Removal of the Crimping Head Unmating the quick–disconnect couplers facilitates removal of the crimping head. Simply disconnect unit from power supply (hydraulic pressure in unit will be released automatically); then, unscrew collar on coupler.

5.

OPERATING PROCEDURE 1. Insert power cord plug into properly grounded receptacle. Refer to power unit specification in Figure 1–1.

The following switches, termed RUN, DUMP, and RESET, are referenced in Figures 5–1 and 5–2.

NOTE

2.

Advance ram partially by: (a) (b)

depressing RESET switch (pilot lamp will light); depressing RUN switch momentarily.

3. Now that dies are partially closed, place terminal or splice in dies.

4. Once again, press RUN switch to advance dies just enough to retain terminal or splice. The dies will maintain a “hold” position long enough to allow the operator to insert wire(s) into a terminal or splice before completing the crimping cycle.

CM 1950

9

BI617075

RUN

RUN DUMP

DUMP

RESET RESET

Fig. 5–1.

Handle Control Switches

cad

Fig. 5–2.

Foot Control Switches

CAUTION

If RUN switch is depressed for too long, the dies will advance fully and crimp the wire barrel of the terminal or splice before wire(s) can be inserted.

NOTE

If it is necessary to retract dies without completing crimping cycle, depress DUMP switch or pressure–release button on power unit electrical control box (Figure 4–1).

5.

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

NOTE

6.

90–48

When crimping large wire splices: if possible, insert stripped wire into both ends of splice so that they butt against wire stops in middle of splice.

If first crimp is made without conductors in both ends, the second conductor may be more difficult to insert due to partial deformation of the splice. Rectangular conductors should be inserted so that crimping pressure is applied to the flat side of the conductors.

6.

Depress RUN switch until power unit completes cycle and dies retract.

7.

Remove crimped terminal or splice.

PREVENTIVE MAINTENANCE

It is important that a preventive maintenance program be established and that maintenance be performed at regular intervals to ensure efficient, dependable performance of the power unit. The preventive maintenance program includes cleaning, visual inspection, checking release/kickoff pressure, and tightening of all external screws and electrical connections.

6.1. Cleaning DANGER

DISCONNECT power unit from power source.

Clean breather hole in hydraulic fluid filler cap frequently, including the area surrounding the filler cap.

10

CM 1950

BI617075

6.2. Visual Inspection (Monthly) DANGER

DISCONNECT power unit from power source.

Perform an overall visual inspection of the power unit at least once a month.

1. Starting at the directional valve and proceeding with your inspection in a clockwise direction around the power unit, check the tightness of all mounting screws and electrical connections. Check tightness of crimping head coupler and hose connections.

2.

Check directional valve cover plate cap screws (Item 57D, Figure 10–5) for tightness.

3.

Check hydraulic fluid level. See Paragraphs 4.2 and 6.3.

4.

Inspect hoses for damage.

5.

Check hydraulic release pressure. See Paragraph 8.2, Pressure Switch Adjustment.

6.3. Hydraulic Fluid Specifications If additional fluid is required for the hydraulic fluid reservoir of the power unit, it is essential that the proper grade of high–quality hydraulic fluid be used. Specifications and examples of high–grade hydraulic fluid for use in the power unit are as follows:

SPECIFICATIONS

EXAMPLES RECOMMENDED HYDRAULIC FLUID

MANUFACTURER

Viscosity Grade 46

Hydro–Drive HP 200

E.F. Houghton & Co.

194–236 Viscosity @ 100_F

DTE 25

Mobil Oil Co.

Pour Point: –20_F Flash Point: 357_F

Telius 46 Rando Oil HD 46

Shell Oil Co. Texaco Inc.

Fire: 430_F Specific Gravity: 28 Neutral Number: .1 Max Condrason Carbon: .05% Refer to Paragraph 4.2 when filling reservoir with fluid.

7.

TROUBLESHOOTING

The following troubleshooting chart is presented as an aid for isolating trouble with the unit. The order of presentation is the normal sequence. The second column lists the probable causes in the order most likely to occur and/or to be checked. The third column lists the remedy for each of the probable causes. The last column contains references to other parts of the manual that should be helpful in remedying the problem.

CM 1950

11

BI617075

TROUBLE

PROBABLE CAUSE

REMEDY

REFERENCE

1. Pilot lamp does not light when RESET switch is depressed.

Electrical plug disconnected, or no power to outlet.

Insert plug or check power to outlet.

——

Switch or power cord is defective.

Replace switch or power cord.

Fig. 3–2

Loose or poor connections inside control box.

Reconnect wiring as required.

Fig. 3–2, 10–2

Handle or foot control not properly plugged into power unit.

Correct

——

Low Voltage.

Check power source.

——

Shorts or loose connections in control box.

Repair.

Fig. 3–2, 10–2

Faulty motor brushes or motor.

Replace.

Para 9.1 or 9.2

Circuit breaker tripped because total amperage draw is too high for existing circuit.

Add an additional circuit or use alternate circuit.

Foreign matter blocking pressure switch.

Clean.

Fig. 8–1

Weak or broken return spring.

Replace.

Fig. 8–1

Loose pressure switch mounting screws.

Tighten.

Fig. 8–1

Faulty RUN switch.

Replace.

Para 9.4 or 9.5

Faulty relays in control box.

Replace.

Para 9.6

Faulty transformer in control box.

Replace.

Para 9.6

Low hydraulic fluid in reservoir.

Refill to not more than 1 inch from top of filler.

Para 6.3

Loose fitting coupler to ram.

Check quick disconnect couplers and coupler ballchecks for wear.

——

Loose or poor connections in control box.

Repair.

Fig. 3–2, 10–2

Improper seating of valve pin in directional valve.

Repair.

Para 9.9(C)

Improper seating of low– pressure check valve.

Repair.

Para 8.3

Defective directional valve coil.

Replace coil.

Para 9.9(A)

2. Unit does not operate when RUN switch is depressed.

(Pilot lamp lights for RESET.)

3. Dies do not advance fully; unit runs continuously but with little or no pressure buildup.

12

——

CM 1950

BI617075

TROUBLE 4. Unit will not shut off.

PROBABLE CAUSE

REMEDY

Pressure switch set higher than 8400 psi.

Reset.

Internal leakage within pump.

Examine mechanism for leaks or foaming of oil in reservoir. If either condition exists, replace the pump.

REFERENCE Para 8.1, 8.2 Fig. 10–6 & Section 11 (Note: AMP Engineering assistance is recommended in this case.)

Faulty safety relief valve.

Replace.

Para 9.7

Faulty relays in control box.

Replace.

Para 9.6

5. Unit performs complete cycle and stops. Dies will not return when DUMP switch is depressed.

Coupler not fully engaged.

Engage couplers completely.

Refer to instruction sheet packaged with head.

Defective crimping head.

Repair.

Refer to instruction sheet packaged with head.

6. Dies will not maintain “hold” position long enough to insert wire and complete crimp cycle.

Defective “O” ring or broken spring in accumulator.

Replace.

Para 9.3

8.

ADJUSTMENTS

The adjustments contained in this section are required to maintain the machine in continuous operation and to set it up following the replacement of parts. The following procedures contain numbered references for identification of parts. These numbered references are found in the parts lists which accompany the exploded views in Section 10, PARTS LISTS AND DRAWINGS. DANGER

ALWAYS disconnect power unit from power source before replacing any parts.

8.1. Pressure Switch Adjustment (Figures 8–1, 8–2, 8–3, and 10–4) If unit continues to cycle with a pressure buildup, the following pressure switch check procedure should be performed: 1. DISCONNECT UNIT FROM POWER SUPPLY. Hydraulic pressure in unit will be released automatically.

2.

Remove pipe plug and install gage. See Figure 8–2.

3.

Reconnect unit to power supply.

CM 1950

13

BI617075

ADJUSTING SCREW LOCK NUT

SETSCREW

SPRING RETAINER RETENTION SCREWS PLATEN SWITCH MOUNTING BRACKET

PRESSURE SWITCH HOUSING WITH COVER REMOVED

SWITCH ADJUSTMENT SCREW

Fig. 8–1.

Pressure Switch Check

90–49

Do not fully cycle unit at this time.

NOTE

4. Bleed air from system by partially cycling unit two or three times. This permits pressure to reach approximately 3,000 psi (according to gage).

5. Now jog the unit through the cycle and read pressure on gage. If gage reads 8,000 to 8,400 psi and unit cycles properly, no adjustment of pressure switch will be necessary. Proceed to Step 9.

If gage reads under 8,000 psi, increase pressure. See (a), Step 6.

If gage reads over 8,400 psi, decrease pressure. See (b), Step 6.

If motor continues to run after unit cycles, immediately release RUN switch. Depress pressure–release button on unit, or DUMP switch on control. Decrease pressure, referring to (b), Step 6.

6.

14

Adjust pressure as follows: (a)

When pressure must be increased (Refer to Figure 8–3): 1.

Loosen the lock nut on the pressure switch. Turn the adjusting screw in a clockwise direction approximately 1/2 turn to increase the pressure to the required setting.

2.

Cycle the unit and check reading on pressure gage. If gage reads 8,000 to 8,400 psi, tighten locking nut while holding the screw; proceed to Step 8. If pressure gage does not read 8,000 to 8,400 psi, repeat previous steps as necessary until pressure gage reads 8,000 to 8,400 psi. If pressure is not consistent, go to 8.2.

(b)

When pressure must be decreased (Refer to Figure 8–3): 1.

Loosen the lock nut on pressure switch. Turn the adjusting screw in a counterclockwise direction approximately 1/2 turn to decrease pressure.

CM 1950

BI617075

2.

3.

4.

Cycle unit and check reading on pressure gage.

Repeat pressure switch adjustment as necessary until pressure gage reads 8,000 to 8,400 psi.

If pressure is not consistent, go to 8.2.

7. After final adjustment of the pressure switch has been made, hold screw in position and tighten lock nut.

8. Make a final cycle and check pressure gage after locking pressure switch adjustment screw in position.

9. DISCONNECT UNIT FROM POWER SUPPLY. Hydraulic pressure in unit will be released automatically.

10. Remove pressure gage; replace pipe plug.

PLUG — REMOVE TO INSTALL PRESSURE GAGE

HYDRAULIC PRESSURE GAGE 0–10,000 PSI RANGE (OTC Y5–BD, or Equivalent)

3/8 NPTF

D MANUFACTURED BY OWATONNA TOOL CO. Fig. 8–2.

Installing Pressure Gage

90–50

8.2. Adjusting Electrical Limit Switch (Figure 8–1) The pressure switch assembly contains a limit switch (microswitch), located within the electrical switch portion of the assembly, which may be adjusted if necessary. Proceed as follows: 1. Remove the top cover of the switch and loosen the retention screws located in the middle of the bottom cover.

2. Place a .020–thick shim between the spring retainer and the platen. Loosen the setscrew and tighten the spring retainer until it contacts the shim. Then lock the spring retainer in place with the setscrew.

CM 1950

15

BI617075

3. Slide the switch mounting bracket towards the platen until the switch button contacts the platen surface. Secure the switch mounting bracket by tightening the two screws located in the middle of the bottom cover.

4. Connect a volt/ohm meter to the electrical cord. Tighten the switch adjustment screw against the switch mounting bracket until the switch button contacts the platen and actuates.

The volt/ohm meter will react when the button actuates and a “click” can be heard. Continue tightening the switch adjustment screw 1/8 turn after the switch button actuates.

5.

Replace the top cover on the switch and secure with the screws.

6.

Set the pressure switch as in 8.1.

8.3. Low–Pressure Check Valve Maintenance (Figures 8–4 and 10–6) If the low–pressure check valve (see Paragraph 3.2.) does not seat properly, hydraulic fluid will leak past the check valve when the valve is closed during high–pressure operation, causing insufficient pressure for operating the crimping head.

The low–pressure check valve is removed and inspected as follows: 1. DISCONNECT UNIT FROM POWER SUPPLY. (Hydraulic pressure in unit will be released automatically.)

2.

Remove the ten reservoir cover screws (77).

3. Lift unit out of reservoir, taking care not to damage reservoir cover gasket (76) and filter (85). Cover reservoir to prevent contamination of fluid.

4.

Remove tubing assembly (84) attached to low–pressure check valve (82).

5.

Remove low–pressure check valve housing from accumulator (87).

6. Remove dirt or foreign matter, if present, from valve pin and housing. If mating surfaces of valve pin or housing are nicked, scored, or grooved, replace check valve (82).

TO DECREASE PRESSURE

TO INCREASE PRESSURE

PRESSURE ADJUSTMENT SCREW LOCKING NUT

ACCUMULATOR VALVE PIN GASKET

HOUSING PRESSURE SWITCH HOUSING TUBING ASSEMBLY

Fig. 8–3.

16

Pressure Adjustment

90–51

Fig. 8–4.

Low–Pressure Check Valve Disassembly

90–52

CM 1950

BI617075

7.

Insert valve pin in housing and install housing. Ensure that gasket on top of housing is in place.

8.

Re–install tubing assembly.

9.

Install reservoir cover gasket (76) and carefully replace unit in reservoir.

10. Secure reservoir cover with the ten screws (77).

9.

REPAIRS AND PARTS REPLACEMENT DANGER

ALWAYS disconnect power unit from power source before replacing any parts.

The procedures described in this section cover those items not shown disassembled in Section 10 which require detailed instructions for repair or replacement of internal parts. Other repairs or replacements can be made by referring to the applicable parts lists and exploded views in Section 10. The numbered references (in parentheses) in this section correspond to the item numbers on the parts lists or drawing referred to in the text.

9.1. Motor Brush Replacement (See Figure 10–3) The carbon brushes should be inspected periodically for excessive wear and good contact. The brushes are inspected as follows: 1.

DISCONNECT POWER UNIT FROM POWER SUPPLY.

2.

Remove four screws (6) and cover plate (5) from each side of motor.

3.

Remove the two caps (2) and brush assemblies (4).

4.

Replace brush(es) if length of brush is less than 1/4 in.

5.

Re–install two caps, cover plates and screws.

9.2. Motor Replacement (See Figure 10–3) Motor replacement will become necessary if shaft bearings become rough or shaft wear is noted. This may be detected by gaining access through the lower vents of the motor, and turning the fan blade. Be certain that the correct motor is specified when ordering a replacement. To install a new motor, proceed as follows: 1.

DISCONNECT UNIT FROM POWER SUPPLY.

2.

Remove cover (10) from electrical control box (9) (Figure 10–2).

NOTE

3.

On some model power units it will be necessary to remove the transformer (7) to gain access to the lower electrical box mounting screw (6) and washer (20). See Figure 10–2. It is not necessary to disconnect the transformer leads.

Disconnect motor wires from inside electrical control box.

4. Remove the two screws (6) and washers (20) (Figure 10–2) that secure the electrical control box to the motor.

CM 1950

17

BI617075

BI617075

BI617075

DISASSEMBLY OF OLD–STYLE HANDLE CONTROL PRIOR TO RETROFIT

SWITCHES FACEPLATE COUPLER

SWITCH MOUNTING PLATE

SWITCH COVER

GRIP SLEEVE

GREEN SWITCH

SWITCH WIRING FOR RETROFIT AND NEWER–STYLE HANDLE CONTROLS

WHITE

RED SWITCH

BROWN

YELLOW SWITCH

ORANGE BLUE

BROWN

RED BLACK

GUARD

ASSEMBLY OF HANDLE CONTROL RETROFIT KIT OR NEWER–STYLE HANDLE CONTROL

COUPLER

SWITCH COVER

GRIP SLEEVE

Fig. 9–2.

20

Handle Control Disassembly, Wiring, and Reassembly

90–54, 200–054E

CM 1950

BI617075

BI617075

BI617075

5. When installing a new safety relief valve, carefully apply a small amount of pipe thread sealant to the relief valve threads and to the internal threads of the high pressure check valve.

CAUTION

Never tamper with the setting of the safety relief valve.

6.

Install reservoir cover gasket (76) and replace unit in reservoir.

7.

Secure with the ten screws (77).

9.8. Filter Maintenance All fluid entering the hydraulic system must pass through the filter. The filter prevents dirt or foreign matter in reservoir from entering the hydraulic system.

The unit should never be operated with a damaged filter or without a filter.

To replace filter, refer to Figure 10–6 and proceed as follows: 1.

Remove unit from reservoir as instructed in Paragraph 9.7, Steps 1, 2, and 3.

2.

Remove threaded filter (85) from bottom of pump.

3.

Attach new filter to bottom of pump.

4.

Install reservoir cover gasket (76) and replace unit in reservoir.

5.

Secure with the ten screws (77).

9.9. Valve Assembly Maintenance (Refer to Figure 10–5) If motor runs but there is no pressure buildup (dies do not close), solenoid control valve coil may be defective (coil does not energize when power unit is activated).

A.

B.

CM 1950

Coil Test 1.

DISCONNECT UNIT FROM POWER SOURCE, and trace coil leads into electrical control box. Ensure that connections are tight and that there are no shorts in coil circuit.

2.

RECONNECT POWER TO UNIT and cycle unit.

3.

If dies do not advance, coil is probably defective and must be replaced (see Paragraph B, Coil Replacement).

Coil Replacement (Refer to Figure 9–4) 1.

DISCONNECT UNIT FROM POWER SUPPLY.

2.

Remove screws from cover plate; remove cover plate.

23

BI617075

NUT SPACER SOLENOID CONTROL VALVE COIL

PRESSURE SWITCH

Fig. 9–4.

C.

Coil Location

90–57

3.

Cut leads on either side of splice, allowing enough length of lead to re–make splice when new coil assembly is installed.

4.

Remove nut, spacer, and “O” ring.

5.

Loosen four hex head screws (See Item 57D, Fig. 10–5) until the solenoid control assembly may be lifted sufficiently to provide enough clearance to remove the faulty coil assembly.

6.

Remove faulty coil assembly and replace with new coil assembly.

7.

Place solenoid control assembly back into position and alternately retighten the four hex screws to 35 in.–lbs of torque.

8.

Re–install “O” ring, spacer, and nut.

9.

Reconnect motor and coil leads (refer to Figure 3–2).

10.

Replace cover plate with the four screws.

Valve Pin Maintenance

If valve pin in solenoid control valve does not seat properly, hydraulic fluid will leak past the pin during high–pressure buildup, returning fluid to the reservoir. Therefore, pressure for crimping may be insufficient.

24

CM 1950

BI617075

Use the following procedure to disassemble the valve assembly. Check condition of the seals, mating surfaces of valve pin, and valve body. Read Paragraph 3.2, refer to Figure 10–5, and proceed as follows: 1.

DISCONNECT POWER UNIT FROM POWER SUPPLY.

2.

Remove the eight socket head screws (59) and two covers (59A) (60) from both ends of valve assembly.

3.

Remove valve pin spring (68) and valve pin (64) from valve assembly.

4.

Remove valve body (66): use a brass drift in end of valve assembly from which valve was removed and tap gently against valve body.

5.

Remove any dirt or foreign matter from valve pin, valve body, or mating surface of valve assembly.

6.

Install new “O” ring (63A) and back–up washer (63B) inside valve body (66).

7.

Install new “O” rings (62) (65) and new back–up washers (71) (69) on outer surface of valve body (66). Apply a thin film of hydraulic fluid (same type used in power unit reservoir) of surface of “O” rings and washers, and insert valve body into valve assembly.

8.

Install new “O” ring (65) on valve pin (64) and insert valve pin and spring (68) into valve assembly (58).

9.

Install new “O” ring (62) on cover (59A) and install cover on valve assembly. Secure with four socket head screws (59).

10.

Install cover (60) with four socket head screws (59).

10. PARTS LISTS AND DRAWINGS This section contains parts lists and exploded–view drawings for the hydraulic power units and handle control assemblies. (The handle control assemblies listed in Figure 2–1 vary according to hose length; therefore, only a single parts listing for the handle control assembly is necessary.) The parts lists identify each assembly and subassembly by a figure number and each part by an item number. The parts lists also provide part number, nomenclature, and quantity required for assembly of the power unit or handle control assembly. Where applicable, the parts lists also provide the particular power unit number in which the part is used.

Certain parts of the hydraulic power units and handle control assemblies are considered “wear” items. It may be advantageous to stock and control wear items to prevent loss of production time when a replacement is necessary. Each wear item is identified in the parts list by a bullet (D) placed immediately after the item number.

CM 1950

25

BI617075

BI617075

MOTOR ASSEMBLY (Fig. 10–3)

PRESSURE SWITCH ASSEMBLY (Fig. 10–4)

CONTROL BOX ASSEMBLY (Fig. 10–2) SOLENOID CONTROL VALVE ASSEMBLY (Fig. 10–5)

VALVE ASSEMBLY (Fig. 10–5A)

RESERVOIR (Fig. 10–6)

ACCESSORY CRIMPING HEADS (Fig. 2–2)

ACCESSORY HANDLE CONTROL (Fig. 10–7)

DUST CAP ACCESSORY, FOOT CONTROL — NOT SHOWN (Fig. 9–3)

Fig. 10–1.

CM 1950

Assemblies, Accessories:

Hydraulic Power Unit 69120–[ ]

90–58, cad

27

BI617075

6

11

20 21

6

20

19

9 22 15 4

5

6

13

15A

1 4

18

23

6

2 3

4

10 ITEM NO.

AMP PART NUMBER

—— —— 1 2 3 4 5 6 7 9 10 11 12 13 14 15 18 19 20

313718–1 313718–2 1– 22242–3 8–306171–7 3– 21016–9 21016–3 3– 21026–6 21018–6 8–306171–8 9–306171–1 9–306171–2 9–306171–3 1– 22538–3 22242–8 1– 21060–3 9–306171–5 3–306171–0 2–306171–9 1–380672–2 21023–7

21 22 23 24

21018–8 28222–1 2– 21016–2 21018–5

28

12

6

20

7

14 DESCRIPTION

QTY

CONTROL BOX ASSY, Power Unit 69120–[ ] (115 Vac) CONTROL BOX ASSY, Power Unit 69120–[ ] (220 Vac) . BUSHING, Strain Relief . RELAY . SCREW, Match, Rnd Hd, 8–32 x .500” L . LOCKWASHER, No. 8, .168 OD x .020” Thk . SCREW, Mach, Rnd Hd, 8–32 x .313” L . NUT, Hex 8–32 . TRANSFORMER, 50/60 Hz . BOX . COVER . BUTTON, Reset . SLEEVE . BUSHING, Strain Relief . SCREW, Slftpg, No. 6 x .313” L . RELAY . CORD SET, Unit 69120–1 . CORD SET, Unit 69120–2 . LIGHT, Indicator . WASHER, Flat, Plain No. 10, .193” ID x .458” OD x .042” Thk . NUT, Hex 10–24 . SOCKET . SCREW . NUT

—— —— 1 1 1 7 2 4 1 1 1 1 1 1 2 1 1 1 1

Fig. 10–2.

90–59

Control Box Assembly

4 2 1 4 2

CM 1950

BI617075

2

4

4

5 2

6

5 6 7

VENTS

1

8

ITEM NO.

AMP PART NUMBER

—— —— 1{ 2 4D 5 6 7 8{

306170–5 306170–6 4–306171–7 3–306171–2 3–306171–4 8–306172–7 21867–3 21001–8 6–306171–5

D WEAR ITEM { NOT INCLUDED IN MOTOR ASSEMBLIES

CM 1950

DESCRIPTION MOTOR ASSY, Power Unit 69120–1 MOTOR ASSY, Power Unit 69120–2 . GASKET, Motor . CAP, Brush . BRUSH ASSY . PLATE . SCREW, Rnd Hd, 10–24 x .375” L . SCREW, Cap, Skt Hd, 1/4–20 x 1.50” L . COUPLING

QTY —— —— 1 2 2 2 8 4 1 90–60

Fig. 10–3.

Motor Assembly

29

BI617075

ITEM NO.

AMP PART NUMBER

DESCRIPTION

QTY

——

313695–1

. PRESSURE SWITCH ASSEMBLY

——

1

313696–1

. CARTRIDGE

1

2 3

2–23877–6 9–306172–0

. SETSCREW (1/4–20 x 3/4 in. L) . ELECTRICAL CORD (2.50 ft, 18/2 SJTO)

1 1

4

16861–1

. BUSHING, Strain Relief

1

5

21076–4

. LOCK WASHER

4

6 7

4–24123–0 22593–6

. SCREW, Machine (#10–24 x 5/16” L) . NUT, Jam (3/8–24)

4 1

8

313697–1

. SCREW, Adjusting

1

9

313698–1

. SPRING RETAINER

1

10

313699–1

. SPRING DISC

1

11 12

21013–3 313705–1

. SETSCREW (1/4–20 x 5/16 in. L) . SPRING, Compression

1 1

13

23241–8

. BALL

1

14

313700–1

. PLATEN

1

15 16

21018–3 313701–1

. NUT (#2–56) . SWITCH BRACKET

2 1

17

313702–1

. SWITCH BODY

1

18

22610–2

. SWITCH, Limit (Microswitch)

1

19

21076–3

. LOCK WASHER

2

20 21

2–24123–9 21102–6

. SCREW, Machine (#8–32 x 5/16” L) . SCREW, Machine (#2–56 x 1/2” L)

2 2

22

313703–1

. PLATE, Cover

2

23

1–21030–0

. PIN, Dowel

1

24

21026–2

. RING, Retaining

1

25 26

313704–1 21053–1

. BUSHING . “O” RING

2 1

27

21106–1

. WASHER, Backup

1

28 {

313707–1

. ELBOW

1

313708–1 981834–1

. FITTING . PLUG

1 1

29 { 30 {

{ NOT INCLUDED WITH PRESSURE SWITCH ASSEMBLY

Fig. 10–4.

30

Pressure Switch Assembly (Sheet 1 of 2)

CM 1950

BI617075

PRESSURE SWITCH ASSEMBLY 313695–1

6

5

7 22

8 9

11

4 3

10 17

12

2 13 1 25 23

15

25

14

24

16 27

18

26 21 22 30

5 28 6 19 20

29

Fig. 10–4.

CM 1950

Pressure Switch Assembly (Sheet 2 of 2)

90–61

31

BI617075

COVER PLATE

57

57D

56 57A

57B

72 57C

ITEM NO.

AMP PART NUMBER

—— 56

312104–1 312057–1

57 57A 57B 57C 57D 72

312058–1 5– 21000–5 4– 21086–5 4– 21086–1 6– 21000–1 312059–1

DESCRIPTION VALVE KIT, Conversion . SOLENOID CONTROL VALVE ASSEMBLY, Power Unit 69120–[ ] 50/60 Hz (Includes Coil [Item 57]) . COIL 50/60 Hz . SCREW, Cap, Skt Hd, 10–24 x .750” L . “O” RING, .500” OD x .063” W . “O” RING, .312” OD x .063” W . SCREW, Cap, Cover Plate, 10–24 x 2.00” L . PLATE, Adapter Fig. 10–5.

32

Solenoid Control Valve Assembly

QTY —— 1 1 4 4 4 4 1 90–62

CM 1950

BI617075

70 63B

59

63A 65

69

68

66

60

71 62

59 58 64

63A 63

65 59A

62 REF FIG. 10–6. ITEM NO. 74A

ITEM NO.

AMP PART NUMBER

—— 58 59 59A 60 62 63 { 63A 63B 64 65 66 68 69 70 { 71

4–306170–1 9–306171–8 3– 21000–5 2–306171–4 306172–1 9– 21053–0 21053–3 21053–7 21050–7 9–306171–6 8– 21053–9 9–306171–7 9–306171–9 21092–4 21001–7 21092–3

{ NOT INCLUDED IN VALVE ASSEMBLY

CM 1950

DESCRIPTION VALVE ASSEMBLY . VALVE HOUSING . SCREW, Cap, Skt Hd, 10–32 x .500” L . COVER . COVER . “O” RING, .750” OD x .063” W . “O” RING, .313” OD x .188” W . “O” RING, .500” OD x .063” W . WASHER, Backup, .500” OD x .063” W . PIN, Valve . “O” RING, .688” OD x .063” W . VALVE BODY . SPRING . WASHER, Backup, .750” OD x .063” W . SCREW, Cap, Skt Hd, 1/4–20 x 1.250” L . WASHER, Backup, .688” OD x .063” W Fig. 10–5A.

Valve Assembly

QTY —— 1 8 1 1 2 1 2 1 1 2 1 1 1 4 2 90–63

33

BI617075

77

87

76A

88 78

75 96A

79

96B 85 81 74A 86 82

80

83

84

76

74

89

ITEM NO.

AMP PART NUMBER

—— 74 74A 75 76 76A 77 78 79 80 81 82 83 84 85 86 87 88 89 96A 96B

—— 2–306171–3 2–306171–5 8–306172–5 1–306171–2 306170–9 6–306171–4 1–306171–3 306170–8 306170–1 1–306171–1 306171–7 306171–8 9–306172–2 306171–4 306172–9 1–306172–0 306171–1 306171–3 21053–7 21050–7

34

DESCRIPTION

QTY

RESERVOIR ASSEMBLY, Power Unit 69120–[ ] . RESERVOIR . TUBING . COVER, Reservoir . GASKET, Reservoir Cover . PUMP . SCREW, Mounting . VALVE, Safety Relief . CHECK VALVE, High–Pressure . TUBING ASSEMBLY . ADAPTER, Male . CHECK VALVE, Low–Pressure . ELBOW . TUBING ASSEMBLY . FILTER . NIPPLE . ACCUMULATOR . PLUG, Filler . CASTER . “O” RING . WASHER, Backup

—— 1 1 1 1 1 10 1 1 1 1 1 1 1 1 1 1 1 4 1 1

Fig. 10–6.

90–64

Reservoir Assembly

CM 1950

BI617075

4 6

7 18

12

17

A 13 14 15 16 (Not Shown) 10

9

1

ITEM NO.

——

1 2 3 4 6 7 8 9 10 12 13 14 15 16 17 18

2

3

AMP PART NUMBER

{ COMES WITHOUT HOSE ASSEMBLY

CM 1950

8

A

59907–7 1– 59907–5 2– 59907–1 2– 59907–8 1– 59908–5 { 2– 59908–1 { 311470–1 1– 21002–8 5– 21016–6 311759–1 311761–1 311758–1 986290–1 986290–2 986290–3 311763–[ ] 8– 22233–7 21026–1 4– 24142–3 320553 307237–1 22242–6

DETAIL A

NOTE: For Switch Wiring see Fig. 9–2.

DESCRIPTION

QTY

HANDLE CONTROL ASSEMBLY, Power Unit 69120–[ ]

——

. . . . . . . . . . . . . . . .

2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1

COUPLER, Quick, Hose Half SCREW, Btn Hd, 6–32 x .50” L SCREW, Slotted Hd 10–32 x .38” L GUARD COVER, Switch GRIP, Handle SWITCH, Mini, (Green) SWITCH, Mini, (Red) SWITCH, Mini, (Yellow) CORD SET, Molded Plug WIRE, Brown, 2” L (Jumper) WASHER SCREW, Bind Hd Mach, 4–40 x .312” L TERMINAL TUBE, Handle STRAIN RELIEF

Fig. 10–7.

Handle Control Assembly

90–65

35