DMC PH1005 Operation Manual

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PH1005 POWER CRIMP TOOL

INTRODUCTION

The PH1005Power Crimp Tool is a pneumatic / hydraulic powered version of the Tyco®49935 hand crimp tool. The basic system consists of a hand held tool (PHMT1005) and the PHRPU4 Remote Power Unit. The Remote Power Unit contains cycle control logic that assures the tool completes the crimp cycle without operator intervention.

IMPORTANT SAFETY INSTRUCTIONS / USER’S RESPONSIBILITIES

When connected together, the PHMT1005 along with the remote power unit, constitute an integrated operating system. Under no circumstances should the crimping tool be attached to any control box or power system other than the control unit provided (PHRPU4). It is imperative that operators using this tool system follow the noted Safety Precautions, be alert at all times and observe the highest level of operator safety.

1. Disconnect from air supply when tool is not in use or when changing dies.

2. Keep all body parts clear of the crimping area while loading and operating the tool.

3. Restrict operation of the PH1005 system to a single operator and follow the directions on the warning labels.

4. Do not alter the tool or operate outside the guidelines specified in this data sheet.

Itis the user’s responsibility to properly train andinstruct alltool operatorsinthe proper use of this tool. The operator must be made aware of the danger of the moving parts, the possibility of serious injury to fingers and other body parts in inserted into the crimp area; and the need to be alert and attentive at all times while using this tool.

SAFETY OPERATION MANUAL

PREPARING TOOL FOR OPERATION (see Figure 1)

The PH1005 Power Crimp Toolconsists of the PHMT1005 CrimpingTool, PHRPU4 Remote Power Unit, PHFV3 Foot Press (optional), and the BM-2 Bench Mount (optional). Four features used for operation or control can be seen on the front panel of the PHRPU4 Remote Power Unit, they include the Hydraulic Quick Disconnect, Dual Coupling Control, Single Coupling Control, and the Input Air Quick Disconnect. Use the following steps to assemble the separate parts:

1. Connectthe hydraulic hose from the PHMT1005 Crimping Tool into the hydraulic quick disconnect on thefront panelof the PHRPU4 Remote Power Unit by pushing back on the lockingringofthehydraulic quick disconnect andpluggingthe male part of the hydraulic hose into the provided area. Theoperator will realize the connection has been made when the locking ring snaps into place.

2. Connect the small tool control hose from the PHMT1005 Crimping Tool to the single coupling control on the front panel of the PHRPU4 Remote Power Unit by pushing the connecting end of hose into the fitting until the spring clip locks into place.

3. Connecttheshop air supply to the air quick disconnect by pulling back on the air hose coupling and inserting the hose into the fitting on the PHRPU4 Remote Power Unit.

4. If PHFV-3 Foot Press is supplied, connect it to the dual coupling control by orienting the connector on the hose so the side marked "TOP" is up, then press inward until the spring clips lock into place.

5. IfBM-2 Bench Mount is supplied, attach ittothe PHMT1005 Crimping Tool by threading themalethreadof the benchmount into the female thread on the tool. Adjust toolto appropriate working position, and lock handle on bench mount.

EMERGENCY STOP BUTTON

ThePHRPU4 Remote Power Unit is configured with an Emergency Stop Button. Bypressingthisbuttonat any time during the crimp cycle, the forward motion on the crimp tool will stop and retract to the open position. Further operation of the system will be inhibited until this Emergency Stop Button is rotated in a clockwise direction and

DANIELS MANUFACTURINGCORP. 526 THORPEROAD, ORLANDO, FL 32824, USA

PHONE (407)855-6161 • FAX (407) 855-6884• WWW.DMCTOOLS.COM • E-MAIL: [email protected]

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PHMT1005

AIR BLEED

(ACTUATOR)

PHFV-3

(OPTIONAL)

DUAL COUPLING CONTROL

HYDRAULIC QUICK DISCONNECT

BM-2

(OPTIONAL)

FIGURE 1

SAFETY OPERATION MANUAL

PHRPU4

EMERGENCY STOP BUTTON

INPUT AIR QUICK DISCONNECT

SINGLE COUPLING CONTROL

allowed to release.

Tool Head Positioning (see Figure 2):

Thetoolheadon the PH1005 Crimping Tool may be rotated to any selectable position relative to the actuator that an operatormightprefer. Toselect or change the head position, loosenthe headposition holding screwso thehead can be turned by hand and rotate head to selected position, then tighten screw.

TOOL OPERATION:

After the PH1005 tool has beenassembled with the dies intheir proper location, the tool isready for operation. Use the following steps to operate the tool properly and safely:

1. Connect the PHRPU4 remote power unit to a standard shop air supply of 80 - 120 psi. (5.5 - 8.3 BAR).

2. Insert component to be crimped in crimp jaws and position properly. The jaws are spring loaded and will hold the part in place.

HYDRAULIC FLUID

AIR BLEED HOLE (SEAL HOLE WITH FINGER TO ACTIVATE TOOL)

FIGURE 2

PRESS HERE TO LOAD AND UNLOAD SPLICE

FILL HOLE

PHMT1005 CRIMP TOOL

HEAD POSITIONING HOLDING SCREW

DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA

PHONE (407) 855-6161 • FAX (407) 855-6884 • WWW.DMCTOOLS.COM • E-MAIL: [email protected]

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SAFETY OPERATION MANUAL

3. Cover the air bleed (actuator) of the tool and start the crimp cycle (see Figure 3).

4. If the Foot Press (PHFV-3) is used, a momentary press will start the crimp cycle.

NOTE: Should the tool not complete its cycle and open, check the supply air pressure. If the pressure reads

below 80 psi(5.5 BAR), bring it back up to a minimum of 80 psi. If the pressure is adequate, push the Emergency Stop Button on the top of the PHRPU4 Remote Power Unit in order to open the tool. It will be necessary to check fluid level as indicated in the next section. Do not use the tool for crimping until this default condition has been corrected.

HYDRAULIC FLUID REFILL:

Use the following procedure to replace lost system hydraulic fluid: PHVG VACUUM GENERATOR (see Figure 3): The PHVG vacuum generator is used with the various PH

series systems for the removal of any air that might be present in the hydraulic hose or in the PHRPU4 intensifier, and the replacement of any fluid loss from leakage or evaporation. Procedure: It is necessary to use the vacuum generator with an amount of hydraulic fluid in the bottom of the fill bowl. Remove the two screws that hold the cover of the bowl and pull it open. With the bowl sitting flat,

PHRPU4 REMOTE POWER UNIT

PHVG CONNECTION

(ADAPTOR)

EMERGENCY STOP BUTTON

SINGLE COUPLING CONTROL

AIR SUPPLY

PHVG HYDRAULIC FILL BOWL

TO PHFV-3 FOOT PRESS

FIGURE 3

coverthe bottom with about 1/4" of ISO46AW hydraulic fluid. Reassemblecover, align holes and tighten down with the two screws just removed. Recharging tools: Plug the male coupling of the tool hose into the female quick disconnect coupling on the PHVG vacuum generator by pulling lock ring back while pushing the male plug in place. The lock ring will snap back in place when released and the male plug is seated. Making sure the fill bowl is level so oil in the bowlcoverstheinputfromthebottomofthebowl,plugintheairsupplyto the fitting provided on the rear of the

DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA

PHONE (407) 855-6161 • FAX (407) 855-6884 • WWW.DMCTOOLS.COM • E-MAIL: [email protected]

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SAFETY OPERATION MANUAL

vacuum generator. As a vacuum is formed, air bubbles will pull through the oil in the bowl and the fluid level willrise slightly. Continueto allow thevacuumgenerator to "run" until there are no noticeablebubbles flowing through the system, or the flow of bubbles is at minimum. Unplug the air supply slowly and watch as the level offluid in the bowl lowers. After waiting about five seconds,thetoolhose can be disconnected from thesystem.

Recharging the PHRPU4: It is necessary to plug the adaptor into the vacuum generator and into the PHRPU4 Remote Power Unit. Holding the fill bowl level with the PHRPU4 sitting on its four feet, plug the air supply into the vacuum generator. Run the unit until there are no air bubbles or they are minimal, then slowly unplug theairsupply.Whentheoillevelnolonger lowers (about five seconds) the generator/adaptor may be uncoupled from the PHRPU4 Remote Power Unit and the tool hose reconnected. If a system default occurs whereby a tool closes and will not open without activating the Emergency Stop Button and the air supply is proper (80 psi./5.5 BAR), charge both the tool and the PHRPU4 to correct the fault. If recharging does not correct the default condition and the air supply is proper, return the system to DMC for service. It is recommended that a peri- odic schedule be maintained for charging the system.Iffluid, other than small amounts, are displaced during the system charging, the schedule should be changed to charge more frequently. If heavy leakage is noted and daily charging is required, the tool/PHRPU4 system should be returned to DMC for seal replacement. It should be noted that small amounts of fluid will be present at the coupling during the charging of the system or when tools are disconnected from the PHRPU4.

OPERATIONALCHARACTERISTICS:

The PH1005 Power Crimp Tool builds up substantial internal hydraulic pressures in attaining the resultant crimp force. This may result in some leakage of hydraulic fluid past the seals in the tool. This does not mean the tools cannot be used. As long as the tools close properly, they will provide an adequate crimp. Add hydraulic fluid as necessary. Where the fluid leakage has become unacceptable, please contact the DMC factory for the proper procedure to return the tool for seal replacement.

GAGING PROCEDURES:

Periodic gaging is suggested to monitor and assure that the proper crimp is being generated in the crimp area.

CAUTION: DO NOT CRIMP GAGE!

"Go" Gaging

With the crimp jaws in fully closed position, insert"Go" gageend intoappropriate cavity. Gage must pass freely through crimping cavity.

"No-Go" Gaging

With the crimp jaws in fully closed position, attempt to insert "No-Go" gage end into the appropriate cavity. Gage may partially enter, but must not pass completely through the cavity.

DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA

PHONE (407) 855-6161 • FAX (407) 855-6884 • WWW.DMCTOOLS.COM • E-MAIL: [email protected]

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WHEN CHECKING GAGING DIMENSIONS, HOLD JAWS TOGETHER TO INSURE A FULLY CLOSED POSITION.

.079

±.003

SAFETY OPERATION MANUAL

GREEN "GO"

RED "NO-GO"

.049

±.003

.057 ±.003

FIGURE 4

GAGING DIMENSIONS FOR PH1005:

CRIMP

CAVITY

22-16 16-14 12-10

"GO"

DIM A

.046 .054 .076

PH1005 SYSTEM COMPONENTS:

PART NUMBER

PHMT1005 PHRPU4 PHVG

"NO-GO"

QTY

1 1 1

DIM B

.052 .060 .082

DESCRIPTION

CRIMPING TOOL REMOTE POWER UNIT VACUUM GENERATOR

GAGE

P/N

G739 G740 G741

GAGE

FIGURE 5

POWER TOOL SYSTEM ACCESSORIES:

PART NUMBER

BM-2 PHFV-3

DESCRIPTION

BENCH MOUNT FOOT PRESS

SAFETY SIGNAGE

Safety signs are placed on the PH1005 Power Crimp Tool to make you aware that this tool could seriously injure or maim you if care is not used while operating it.

Thesesignsareintended as a constant reminder of the potential risk involved. Thesesigns should never beremoved and should be replaced as needed. Signs alone will not prevent accidents from occurring. Operators must be properly trained in the use of the equipment and be aware of the risks involved. While using the tool, it is important to be alert and avoid distractions.

DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA

PHONE (407) 855-6161 • FAX (407) 855-6884 • WWW.DMCTOOLS.COM • E-MAIL: [email protected]

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SAFETY OPERATION MANUAL

DISCONNECT FRDISCONNECT FR

DISCONNECT FR

DISCONNECT FRDISCONNECT FR BEFOREBEFORE

BEFORE

BEFOREBEFORE TT

OOL OR DIESOOL OR DIES

OOL OR DIES

OOL OR DIESOOL OR DIES

TTEMPTINGTTEMPTING

TTEMPTING

TTEMPTINGTTEMPTING

OMOM

AIR SUPPLAIR SUPPL

AIR SUPPL

OMOM

AIR SUPPLAIR SUPPL

ADJUSTADJUST

ADJUST

ADJUSTADJUST

FINGER FREE AREAS

EMERGENCY STOP

Daniels Manufacturing Corporation offers complete refurbishing and recalibration services. DMC specially engineers and manufactures complete tool kits to satisfy individual customer requirements, such as total aircraft support, general shop maintenance or production, on board ship and vehicle service, etc.

LIMITATION OF LIABILITY/LIMITED WARRANTY*

DMC (DANIELS MANUFACTURING CORP.) IS NOT LIABLE FOR CONSEQUENTIAL ORSPECIAL DAMAGESOF ANY NATURE OR KIND RESULTING FROM THE USE,OR MISUSE,OF ANY OF ITS PRODUCTS. OWNERS AND USERS OF DMC PRODUCTS ASSUME FULL RESPONSIBILITY FOR INSTRUCTING OPERATORS IN THE PROPER AND SAFE USE OF SUCH PRODUCTS. OPERATORSASSUME FULLRESPONSIBILITYFOR OPERATING DMCPRODUCTSIN ASAFEMANNER AND ACCORDING TO DMC OPERATING INSTRUCTIONS.

DMC (Daniels Manufacturing Corp.) warrants each new product sold by it to be free from defects in materialand workmanship under normal use and service. DMC'sobligation under this warranty is limitedtothe freecorrectionor, at DMC's option, the refund of the purchase price of any suchproduct whichproves defective in normal service within ninety (90) days after delivery to the first user, provided that the product is returned to DMCwithalltransportationchargesprepaid and which shall appear to DMC's satisfaction, after DMC's inspection, to have been defective in material or workmanship, it being understood that DMC products are not consumer products. This warranty shall not cover any damage to any product which, in the opinion of DMC, was caused by normal wear, misuse, improper operation, tampering, neglect or accident.

This limited warranty is in lieu of all other warranties express or implied, including, but not limited to, warranties of fitness for aparticular purpose and warranties ofsafe operation. No warranty, express or implied, is made or authorized to be made or assumed with respect to products of Daniels Manufacturing Corporation, other than that herein set forth.

*as defined by PL93-637

DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA

PHONE (407) 855-6161 • FAX (407) 855-6884 • WWW.DMCTOOLS.COM • E-MAIL: [email protected]

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