idt-12-n hydraulic crimping tool - ilsco

INSTRUCTION MANUAL

99945282 REV 6 © 2009 Ilsco Corporation Q.F.5.4.55 2/09

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.

IDT-12-NHydraulic Crimping Tool

Ilsco Corporation 2 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775

IDT-12-N Hydraulic Crimping Tool

KEEP THIS MANUAL

Table of ContentsDescription ..................................................................... 2

Safety ............................................................................. 2

Purpose of this Manual .................................................. 2

Warranty and Service ..................................................... 2

Important Safety Instructions ..................................... 3–4

Identification ................................................................... 5

Specifications ................................................................. 5

Operation .................................................................... 6–7

Periodic Pressure Relief Valve Check............................. 8

Maintenance ................................................................... 8

Troubleshooting .............................................................. 9

AirPurgingandOilFillingProcedure ............................ 10

Illustration ..................................................................... 11

Parts List ...................................................................... 12

DescriptionTheIDT-12-NHydraulicCrimpingToolisahand-held,self-contained,dielesscrimpingtoolintendedtocrimpaluminum and copper connectors onto electrical cable.

Thehingedcrimpinghead,whichallowseasyloadingandunloadingofspliceconnections,swivels180°formaximumflexibility.Thetwo-speedhydraulicsystemautomaticallyswitchesfromrapidadvance(forquicksnug-up)tonormaladvance(toaccomplishthecrimp).An internal pressure regulating system automatically sets the correct pressure for the connector.

SafetySafety is essential in the use and maintenance of Ilsco toolsandequipment.Thismanualandanymarkingsonthe tool provide information for avoiding hazards and unsafepracticesrelatedtotheuseofthistool.Observeall of the safety information provided.

Purpose of this ManualThismanualisintendedtofamiliarizeallpersonnelwith the safe operation and maintenance procedures for the followingIlscotool:

IDT-12-NHydraulicCrimpingTool

Keep this manual available to all personnel.

Replacementmanualsareavailableuponrequestat no charge.

Warranty and ServiceILSCOwarrantsthistooltotheoriginalpurchaserforaperiodofoneyearfromthedateofpurchase,providedthetoolisoperated,maintainedandusedinaccordancewithILSCO’swritteninstructions.Ordinarywearandtear,damagefromabuse,neglectoralterationsarenotcoveredbythiswarranty.Thiswarrantyisnullandvoid if instructions and operating procedures are not followed.ContactILSCOforallwarrantyandserviceissuesat800-776-9775.

DowCorningisaregisteredtrademarkandRTVSealant732isatrademarkofDowCorningCorporation.

Univis is a registered trademark of Exxon Mobil Corporation.



IMPORTANT SAFETY INFORMATION

Electricshockhazard:

This tool is not insulated. When using this unit near energized electrical lines,useproperpersonalprotectiveequipment.

Failuretoobservethiswarningcouldresult in severe injury or death.

Weareyeprotectionwhenoperatingor servicing this tool.

Failuretoweareyeprotectioncouldresult in serious eye injury from flying debris or hydraulic oil.

Skininjectionhazard:

Do not use hands to check for •leaks.

Depressurize the hydraulic system •before servicing.

Oilunderpressureeasilypuncturesskincausingseriousinjury,gangreneor death. If you are injured by escapingoil,seekmedicalattentionimmediately.

SAFETY ALERT SYMBOL

This symbol is used to call your attention to hazards orunsafepracticeswhichcouldresultinaninjuryorpropertydamage.Thesignalword,definedbelow,indicates the severity of the hazard. The message afterthesignalwordprovidesinformationforpreventing or avoiding the hazard.

Immediatehazardswhich,ifnotavoided,WILLresultin severe injury or death.

Hazardswhich,ifnotavoided,COULDresultinsevere injury or death.

Hazardsorunsafepracticeswhich,ifnotavoided,MAY result in injury or property damage.

Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.




IMPORTANT SAFETY INFORMATION

An incomplete crimp can cause a fire.

Use proper connector and cable combinations. •Improper combinations can result in an incomplete crimp.

The relief valve sounds to indicate a completed •crimp. If you do not hear the sound of the relief valve,thecrimpisnotcomplete.

Failuretoobservethesewarningscouldresultinsevere injury or death.

Inspecttoolbeforeuse.Replaceanywornordamaged parts. A damaged or improperly assembled tool can break and strike nearby personnel.

Failuretoobservethiswarningcouldresultinsevereinjury or death.

Keephandsawayfromthecrimpingtoolheadwhencrimping.


Thistoolisintendedfortwo-handedoperation.•Maintain a firm grip on both handles during opera-tion. Using this tool in any other manner can result in injury or property damage.

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 and property damage.

Note: Keep all decals clean and legible, and replace when necessary.



Identification

Specifications

Crimping Tool

Length ..........................................................................................................673mm(26.5")

Width ...........................................................................................................26.3mm(2.87")

Mass/Weight .................................................................................................7.5kg(16.5lb)

HydraulicOil ...................................................................................................198cc(12in3)

Crimping Capacities

Crimping Range

Copper Connectors .................................. 25 mm2 to 500 mm2(#4AWGto1000Kcmil)

Aluminum Connectors .............................. 16mm2 to 500 mm2(#6AWGto1000Kcmil)

Maximum Crimping Tool Diameter ........................................................461mm(1.815")

CrimpingForce(maximum) ........................................................................ 133kN(15tons)

Crimping tool adjusts automatically to connector size.

MovablePin Unit

ReleaseTrigger

Ram Die

Die Head



Operation

Electricshockhazard:

This tool is not insulated. When using this unit near energized electrical lines,useproperpersonalprotectiveequipment.


Weareyeprotectionwhenoperatingor servicing this tool.

Failuretoweareyeprotectioncouldresult in serious eye injury from flying debris or hydraulic oil.

Skininjectionhazard:

Do not use hands to check for •leaks.

Depressurize the hydraulic system •before servicing.

Oilunderpressureeasilypuncturesskincausingseriousinjury,gangreneor death. If you are injured by escapingoil,seekmedicalattentionimmediately.

An incomplete crimp can cause a fire.

Use proper connector and cable combinations. •Improper combinations can result in an incomplete crimp.

The relief valve sounds to indicate a completed •crimp. If you do not hear the sound of the relief valve,thecrimpisnotcomplete.

Failuretoobservethesewarningscouldresultinsevere injury or death.

Inspecttoolbeforeuse.Replaceanywornordamaged parts. A damaged or improperly assembled tool can break and strike nearby personnel.

Failuretoobservethiswarningcouldresultinsevereinjury or death.

Keephandsawayfromthecrimpingtoolheadwhencrimping.




Operation (cont’d)

Preparation

1. Selectapropersizeandtypeofconnectortocorre-spondwiththewireorcable.

2. Stripthecabletoanappropriatelength.Followtheinstructions in the Ilsco stuffer sheet.

Note: Apply an oxide inhibitor, if required. Refer to the Ilsco stuffer sheet.

Crimping

1. Insertthecablefullyintotheconnector.

2. Position the connector in the crimping head.

Note: Position the lug connectors so the tang is perpendicular to the direction of ram travel, as shown.

Direction of Ram TravelTang

3. Ifopen,closethedieheadandpushinthemovable pin unit. Make sure the movable pin is fully engaged.

4. Alignthetoolwiththealignmentmark(forlugs)orcenterstop(forsleeves)asshown.

OUTERMOSTBLADE OF DIE HEAD

LUGALIGNMENT

MARK

LONGER LUG

TANG

OUTERMOSTBLADE OF RAM DIE

LUGALIGNMENT

MARK

SHORTER LUG

TANG

OUTERMOSTBLADE OF DIE HEAD

CENTERSTOP

SLEEVE

5. Pump the handle to advance the ram. Continue to pump until the pressure relief valve activates.

Note: Pressure relief is indicated by an audible “pop” and a sudden drop in handle force.

6. Toreleasethehydraulicpressure,pullthereleasetriggerbackwhilepressingdownonthehandle.

Note: To prevent the ram from retracting completely, release the trigger. This speeds the crimping process when a single connector requires several crimps.

7. Complete the number of crimps specified in the Ilsco stuffer sheet.

8. Toremovethetoolfromasplice,pullthemovablepin on the die head and open the crimping head.



Periodic Pressure Relief Valve CheckTest the crimping tool periodically to ensure that the pressure relief valve activates at the proper pressure. Orderacrimpingtooltestkit,Ilscopartnumber 50328913.

The pressure test slugs are manufactured to a precise diameterandhardness.Donotre-usethetestslugs.Discard each slug after use.

Testing the Crimping Tool

1. Centeranewpressuretestsluginthecrimpinghead.

2. Pump the handles to advance the ram. Continue to pump until the pressure relief valve activates.

3. Toreleasethehydraulicpressure,pullthereleasetriggerbackwhilepressingdownonthehandle.

4. RepeatSteps1through3ontwomoretestslugs.

5. Testthethreeslugsasfollowsagainstthe GO/NOGOgaugeasshown.

• IftheGOslotfitsovertheslugandtheNOGOslotdoesnot,thepressureiswithinthespecifiedrange.

• IftheGOslotdoesnotslideovertheslug,thecrimpingpressureistoolow.Sendthecrimpingtool to Ilsco.

• IftheNOGOslotslidesovertheslug,thecrimp-ing pressure is too high. Send the crimping tool to Ilsco.

MaintenanceAfterusingthetool,removeanydirt,grit,oroxide•inhibitor from the tool.

Occasionallylubricatemovingparts.•

Storethetoolinitscasewiththeramfullyretracted.•

Perform the Periodic Pressure Relief Valve Check •every500crimpsorevery90days,whichevercomesfirst.

GO Gauge NO GO Gauge

Check Point (center depression of the three depression side)

6. Discard the slugs.



Troubleshooting

Ramdoesnotadvance. Airinthehydraulicsystem. Referto“AirPurgingandOilFillingProcedure.”

Check valve or release mechanism. Return tool to Ilsco.

Ramadvancesslowly. Airinthehydraulicsystem. Referto“AirPurgingandOilFillingProcedure.”

Check valve or release mechanism. Return tool to Ilsco.

Ramadvanceserratically. Airinthehydraulicsystem. Referto“AirPurgingandOilFillingProcedure.”

Ramretractspartiallywith Airinthehydraulicsystem. Referto“AirPurgingandOilFillingProcedure.”each stroke. Check valve. Return tool to Ilsco.

Ramdoesnotfullyadvance. Hydraulicfluidlevelislow. Referto“AirPurgingandOilFillingProcedure.”

Ramdoesnotfullyretract. Airinthehydraulicsystem. Referto“AirPurgingandOilFillingProcedure.”

Reservoirisoverfilled. Referto“AirPurgingandOilFillingProcedure.”

Internal binding. Return tool to Ilsco.

Ram does not retract. Dies damaged. Return tool to Ilsco.

Release mechanism. Return tool to Ilsco.

Pressurebuildsslowly; Dischargecheckball. Flushvalveseatusingrapidpumpstrokes.handlespringsback. Ifunitstilldoesnotwork,returntooltoIlsco.

Pressurebuildsslowly; Reliefvalveorreleasemechanism. ReturntooltoIlsco.no response.

Nohighpressure. Checkvalve. Flushvalveseatusingrapidpumpstrokes. Ifunitstilldoesnotwork,returntooltoIlsco.

Airinhydraulicsystem. Improperfillprocedure. Referto“AirPurgingandOilFillingProcedure.”

Loose or missing reservoir plug. Replace plug.

Reservoir damaged. Replace reservoir.

ReservoirmissingO-ring. ReplaceO-ring.

DamagedO-ringonlowpressure ReturntooltoIlsco. injector.

Probable CauseProblem Probable Remedy



Air Purging and Oil Filling ProcedureFillthereservoirwithExxonUnivis® J26 all temperature hydraulic oil only.

Donotfillthehydraulicreservoirwithanyothertypeoffluid(suchasbrakefluid,glycerine,castoroil,etc.).

Fillingthereservoirwithanythingotherthanhydraulicfluidwilldamagethetoolandvoidthewarranty.

2. Retract the ram by pulling the release trigger back whilepressingdownonthehandle.

3. Pump the handle one partial stroke.

4. Peelouttherubberplug(26)andremovethesetscrew(27)fromthereservoirhandle(1).

8. Pump the handle several times to advance the ram. While holding a cleanshopclothoverthereservoir,retract the ram fully. Repeat several times to purge all of the air from the system.

9. With the pump handle vertical and the ram fully retracted,fillthereservoiruntilitoverflows.

10.Replacetheplug(25)andwipeoffexcessoil.

11.Pumpthehandleonestrokeandinstallthereservoirhandle(1).Replacethesetscrew(27).

12.Coverthesetscrewwithasiliconerubbersealant,suchasDowCorning®RTVSealant732™Multi-Purpose Sealant.

1. Clampthetoolintoavisewithjawprotectorssothehandlesareupward,asshown.

5. Unscrewthereservoirhandlefromthecrimpingtool.Removetheplug(25)fromthereservoir.

6. Retract the ram fully.

7. Addoiluntilthereservoiroverflows.

Vise with JawProtectors

Rubber Plug (26)

Remove set screw (27).

ReservoirPlug (25)



Illustration

7

17

29

5

4

23

23

24

25

22

1621

27

26

1

18

19

20

28

15

1614

13*

10

11 12

8

156

9

Torq

ue c

ap s

crew

s (1

3)to

20.

3 Nm

(15

ft-lb

).



Parts List Key Part No. Description Qty

U.S. TECHNICAL SUPPORT1-800-776-9775

IlscoCorporation•4730MadisonRoad,Cincinnati,Ohio 45227-1426Phone(800)776-9775,(513)533-6200•Fax(513)871-4084E-mail: [email protected]•Website: http://www.ilsco.com

1 50014501 Handle,reservoir.................................................................................1 2 50356895 Grip,reservoirhandle .........................................................................1 50014480 Handleunit,pump(includesitems3–11) ...........................................1 3 50356887 Grip,rubber ........................................................................................1 4 50014498 Handle,pump .....................................................................................1 5 90510488 Pin,roll,.125x.625 ............................................................................1 6 90534751 Pin,roll,.156x1.375 ..........................................................................2 7 50356984 Rod,pressurerelease .........................................................................1 8 90504585 Pin,roll,.125x.375 ............................................................................1 9 50034278 Trigger,release ....................................................................................1 10 50033344 Spring,torsion,.187x.280x.312 .....................................................1 11 50356976 Bar,pressurerelease ..........................................................................1 12 50324934 Lever,pivot .........................................................................................1 13 90512650 Screw,cap,1/4–20x.750sockethead .............................................2 14 50356763 Pin,fulcrum .........................................................................................1 15 90523369 Ring,retaining,.312Truarc .................................................................2 16 90513797 Ring,retaining,.500Truarc .................................................................2 17 50325140 Die,ram ..............................................................................................1 18 50356771 Head,die ............................................................................................1 19 52047204 Detent,ball .........................................................................................1 20 90523385 Screw,set,#10-32x.250socket .....................................................1 21 50356780 Pinunit,movable ................................................................................1 22 50356739 Pin,pivot,.468x2.05 .........................................................................1 23 90538145 O-ring,1.47x1.71x.118 ...................................................................1 24 50356860 Reservoir .............................................................................................1 25 50324888 Plug,rubberreservoir .........................................................................1 26 DowCorningSilastic732RTV(clearorblue) ......................as needed 27 90512413 Screw,set,#10–32x.187socketflatpoint ........................................1 28 50337300 Spacer,.549x.997x.025 ...................................................as needed 50014277 Carryingcase ......................................................................................1 50062468 Calibrationtestkit(includes30testslugsandgauge) .......................1 50353730 Exxon Univis J26 hydraulic oil .............................................as needed 50328921 Gaugepressuretest ...........................................................................1 503 28930 Slug pressure test ...............................................................................7

Decals 29 50014293 Decal,warning ....................................................................................1 50014765 Decal,case .........................................................................................1 50062433 Decal,instruction/operating ...............................................................1 50062336 Decal,safety .......................................................................................1 50014463 Decal,toolidentification .....................................................................2

Printed in the USA

idt-12-n hydraulic crimping tool - ilsco

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