INSTRUCTION MANUAL IDT-12-N Hydraulic Crimping Tool Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. 99945282 REV 6 2009 Ilsco Corporation Q.F.5.4.55 2/09
Table of Contents Description... 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 Air Purging and Oil Filling Procedure... 10 Illustration... 11 Parts List... 12 Description The IDT-12-N Hydraulic Crimping Tool is a hand-held, self-contained, dieless crimping tool intended to crimp aluminum and copper connectors onto electrical cable. The hinged crimping head, which allows easy loading and unloading of splice connections, swivels 180 for maximum flexibility. The two-speed hydraulic system automatically switches from rapid advance (for quick snug-up) to normal advance (to accomplish the crimp). An internal pressure regulating system automatically sets the correct pressure for the connector. Safety Safety is essential in the use and maintenance of Ilsco tools and equipment. This manual and any markings on the tool provide information for avoiding hazards and unsafe practices related to the use of this tool. Observe all of the safety information provided. Purpose of this Manual This manual is intended to familiarize all personnel with the safe operation and maintenance procedures for the following Ilsco tool: IDT-12-N Hydraulic Crimping Tool Keep this manual available to all personnel. Replacement manuals are available upon request at no charge. Warranty and Service ILSCO warrants this tool to the original purchaser for a period of one year from the date of purchase, provided the tool is operated, maintained and used in accordance with ILSCO s written instructions. Ordinary wear and tear, damage from abuse, neglect or alterations are not covered by this warranty. This warranty is null and void if instructions and operating procedures are not followed. Contact ILSCO for all warranty and service issues at 800-776-9775. Dow Corning is a registered trademark and RTV Sealant 732 is a trademark of Dow Corning Corporation. Univis is a registered trademark of Exxon Mobil Corporation. KEEP THIS MANUAL Ilsco Corporation 2 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
IMPORTANT SAFETY INFORMATION SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. 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. Immediate hazards which, if not avoided, WILL result in severe injury or death. Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil. Hazards which, if not avoided, COULD result in severe injury or death. Hazards or unsafe practices which, if not avoided, 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. Failure to observe this warning could result in severe injury or death. Skin injection hazard: Do not use hands to check for leaks. Depressurize the hydraulic system before servicing. Oil under pressure easily punctures skin causing serious injury, gangrene or death. If you are injured by escaping oil, seek medical attention immediately. Ilsco Corporation 3 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
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, the crimp is not complete. Failure to observe these warnings could result in severe injury or death. Inspect tool before 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. Keep hands away from the crimping tool head when crimping. Failure to observe this warning could result in severe injury or death. This tool is intended for two-handed operation. Maintain a firm grip on both handles during operation. 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. Ilsco Corporation 4 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Identification Release Trigger Ram Die Die Head Movable Pin Unit Specifications Crimping Tool Length... 673 mm (26.5") Width... 26.3 mm (2.87") Mass/Weight...7.5 kg (16.5 lb) Hydraulic Oil...198 cc (12 in 3 ) Crimping Capacities Crimping Range Copper Connectors... 25 mm 2 to 500 mm 2 (#4 AWG to 1000 Kcmil) Aluminum Connectors... 16 mm 2 to 500 mm 2 (#6 AWG to 1000 Kcmil) Maximum Crimping Tool Diameter... 461 mm (1.815") Crimping Force (maximum)... 133 kn (15 tons) Crimping tool adjusts automatically to connector size. Ilsco Corporation 5 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Operation 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. 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, the crimp is not complete. Failure to observe these warnings could result in severe injury or death. Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil. Inspect tool before 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. Skin injection hazard: Do not use hands to check for leaks. Depressurize the hydraulic system before servicing. Oil under pressure easily punctures skin causing serious injury, gangrene or death. If you are injured by escaping oil, seek medical attention immediately. Keep hands away from the crimping tool head when crimping. Failure to observe this warning could result in severe injury or death. Ilsco Corporation 6 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Operation (cont d) Preparation 1. Select a proper size and type of connector to correspond with the wire or cable. 2. Strip the cable to an appropriate length. Follow the instructions in the Ilsco stuffer sheet. Note: Apply an oxide inhibitor, if required. Refer to the Ilsco stuffer sheet. Crimping 1. Insert the cable fully into the connector. 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. 4. Align the tool with the alignment mark (for lugs) or center stop (for sleeves) as shown. TANG LUG ALIGNMENT MARK LONGER LUG SHORTER LUG OUTERMOST BLADE OF DIE HEAD TANG LUG ALIGNMENT MARK OUTERMOST BLADE OF RAM DIE Tang Direction of Ram Travel SLEEVE 3. If open, close the die head and push in the movable pin unit. Make sure the movable pin is fully engaged. CENTER STOP OUTERMOST BLADE OF DIE HEAD 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. To release the hydraulic pressure, pull the release trigger back while pressing down on the handle. 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. To remove the tool from a splice, pull the movable pin on the die head and open the crimping head. Ilsco Corporation 7 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Periodic Pressure Relief Valve Check Test the crimping tool periodically to ensure that the pressure relief valve activates at the proper pressure. Order a crimping tool test kit, Ilsco part number 50328913. The pressure test slugs are manufactured to a precise diameter and hardness. Do not re-use the test slugs. Discard each slug after use. Maintenance After using the tool, remove any dirt, grit, or oxide inhibitor from the tool. Occasionally lubricate moving parts. Store the tool in its case with the ram fully retracted. Perform the Periodic Pressure Relief Valve Check every 500 crimps or every 90 days, whichever comes first. Testing the Crimping Tool 1. Center a new pressure test slug in the crimping head. 2. Pump the handles to advance the ram. Continue to pump until the pressure relief valve activates. 3. To release the hydraulic pressure, pull the release trigger back while pressing down on the handle. 4. Repeat Steps 1 through 3 on two more test slugs. 5. Test the three slugs as follows against the GO/NO GO gauge as shown. If the GO slot fits over the slug and the NO GO slot does not, the pressure is within the specified range. If the GO slot does not slide over the slug, the crimping pressure is too low. Send the crimping tool to Ilsco. If the NO GO slot slides over the slug, the crimping pressure is too high. Send the crimping tool to Ilsco. Check Point (center depression of the three depression side) GO Gauge NO GO Gauge 6. Discard the slugs. Ilsco Corporation 8 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Troubleshooting Problem Probable Cause Probable Remedy Ram does not advance. Air in the hydraulic system. Refer to Air Purging and Oil Filling Procedure. Check valve or release mechanism. Return tool to Ilsco. Ram advances slowly. Air in the hydraulic system. Refer to Air Purging and Oil Filling Procedure. Check valve or release mechanism. Return tool to Ilsco. Ram advances erratically. Air in the hydraulic system. Refer to Air Purging and Oil Filling Procedure. Ram retracts partially with Air in the hydraulic system. Refer to Air Purging and Oil Filling Procedure. each stroke. Check valve. Return tool to Ilsco. Ram does not fully advance. Hydraulic fluid level is low. Refer to Air Purging and Oil Filling Procedure. Ram does not fully retract. Air in the hydraulic system. Refer to Air Purging and Oil Filling Procedure. Reservoir is overfilled. Internal binding. Refer to Air Purging and Oil Filling Procedure. Return tool to Ilsco. Ram does not retract. Dies damaged. Return tool to Ilsco. Release mechanism. Return tool to Ilsco. Pressure builds slowly; Discharge check ball. Flush valve seat using rapid pump strokes. handle springs back. If unit still does not work, return tool to Ilsco. Pressure builds slowly; Relief valve or release mechanism. Return tool to Ilsco. no response. No high pressure. Check valve. Flush valve seat using rapid pump strokes. If unit still does not work, return tool to Ilsco. Air in hydraulic system. Improper fill procedure. Refer to Air Purging and Oil Filling Procedure. Loose or missing reservoir plug. Reservoir damaged. Reservoir missing O-ring. Damaged O-ring on low pressure injector. Replace plug. Replace reservoir. Replace O-ring. Return tool to Ilsco. Ilsco Corporation 9 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Air Purging and Oil Filling Procedure Fill the reservoir with Exxon Univis J26 all temperature hydraulic oil only. 5. Unscrew the reservoir handle from the crimping tool. Remove the plug (25) from the reservoir. Do not fill the hydraulic reservoir with any other type of fluid (such as brake fluid, glycerine, castor oil, etc.). Filling the reservoir with anything other than hydraulic fluid will damage the tool and void the warranty. 1. Clamp the tool into a vise with jaw protectors so the handles are upward, as shown. Reservoir Plug (25) Vise with Jaw Protectors Rubber Plug (26) 6. Retract the ram fully. 7. Add oil until the reservoir overflows. 2. Retract the ram by pulling the release trigger back while pressing down on the handle. 3. Pump the handle one partial stroke. 4. Peel out the rubber plug (26) and remove the set screw (27) from the reservoir handle (1). Remove set screw (27). 8. Pump the handle several times to advance the ram. While holding a clean shop cloth over the reservoir, 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, fill the reservoir until it overflows. 10. Replace the plug (25) and wipe off excess oil. 11. Pump the handle one stroke and install the reservoir handle (1). Replace the set screw (27). 12. Cover the set screw with a silicone rubber sealant, such as Dow Corning RTV Sealant 732 Multi- Purpose Sealant. Ilsco Corporation 10 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Illustration 3 2 1 4 29 27 26 5 25 6 24 11 12 15 7 10 13* 14 16 23 Torque cap screws (13) to 20.3 Nm (15 ft-lb). 9 8 15 22 17 28 16 21 20 19 18 Ilsco Corporation 11 4730 Madison Rd. Cincinnati, OH 45227-1426 800/776-9775
Parts List Key Part No. Description Qty 1 50014501 Handle, reservoir...1 2 50356895 Grip, reservoir handle...1 50014480 Handle unit, pump (includes items 3 11)...1 3 50356887 Grip, rubber...1 4 50014498 Handle, pump...1 5 90510488 Pin, roll,.125 x.625...1 6 90534751 Pin, roll,.156 x 1.375...2 7 50356984 Rod, pressure release...1 8 90504585 Pin, roll,.125 x.375...1 9 50034278 Trigger, release...1 10 50033344 Spring, torsion,.187 x.280 x.312...1 11 50356976 Bar, pressure release...1 12 50324934 Lever, pivot...1 13 90512650 Screw, cap, 1/4 20 x.750 socket head...2 14 50356763 Pin, fulcrum...1 15 90523369 Ring, retaining,.312 Truarc...2 16 90513797 Ring, retaining,.500 Truarc...2 17 50325140 Die, ram...1 18 50356771 Head, die...1 19 52047204 Detent, ball...1 20 90523385 Screw, set, #10-32 x.250 socket...1 21 50356780 Pin unit, movable...1 22 50356739 Pin, pivot,.468 x 2.05...1 23 90538145 O-ring, 1.47 x 1.71 x.118...1 24 50356860 Reservoir...1 25 50324888 Plug, rubber reservoir...1 26 Dow Corning Silastic 732 RTV (clear or blue)...as needed 27 90512413 Screw, set, #10 32 x.187 socket flat point...1 28 50337300 Spacer,.549 x.997 x.025...as needed 50014277 Carrying case...1 50062468 Calibration test kit (includes 30 test slugs and gauge)...1 50353730 Exxon Univis J26 hydraulic oil...as needed 50328921 Gauge pressure test...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, tool identification...2 U.S. TECHNICAL SUPPORT 1-800-776-9775 Ilsco Corporation 4730 Madison Road, Cincinnati, Ohio 45227-1426 Phone (800) 776-9775, (513) 533-6200 Fax (513) 871-4084 E-mail: sales@ilsco.com Web site: http://www.ilsco.com Ilsco Corporation 12 4730 Madison Rd. Cincinnati, OH 45227-1426 Printed 800/776-9775 in the USA