TBHD1 CRIMPING TOOL FOR THOMAS & BETTS TS DIES DATASHEET SEE PAGE 6 FOR IMPORTANT INFORMATION CONCERNING LIMITED WARRANTY, AND LIMITATION OF LIABILITY Operating instructions for the TBHD1 crimping tool using the HPU10 air/hydraulic pump or the hand operated MHP-1 hydraulic pump BRIDGE BRIDGE PIN PIVOT PIN FILLER CAP CLOSE STATIONARY DIE MOVABLE DIE OPEN VALVE KNOB MHP-1 HYDRAULIC PUMP FIGURE 1 TBHD1 CRIMPING TOOL QUICK CONNECTION INSTALLING DIES: 1. Pull both pivot and bridge pins to remove the bridge as shown in Figure 1. 2. Place the movable die half between the die rails. Carefully lower the die and mate the die snap retainer to the snap retainer located in the ram as shown in Figure 2. 3. Place the stationary die half between the rails and lower it so the flat spring fits into the spring recess of the die rails. 4. Replace the bridge onto the die rails and snap the stationary die into the mating snap located in the bridge. 5. Replace both the bridge and pivot pins. (CAUTION: THE STATIONARY DIE SNAP AND BRIDGE SNAP RETAINERS MUST BE FULLY EN- GAGED BEFORE THE PINS CAN BE INSTALLED.) CAUTION: DO NOT OPERATE THIS TOOL WITHOUT A DIE SET INSTALLED AND THE BRIDGE PROPERLY ATTACHED AND LOCKED WITH THE BRIDGE PIN AND PIVOT PIN. COPYRIGHT 2002 ALL RIGHTS RESERVED 1
STATIONARY DIE SNAP FLAT DIE SPRING BRIDGE SNAP RETAINER RAM SNAP DIE SNAP RETAINER MOVABLE DIE SNAP FIGURE 2 FLAT DIE SPRING RECESS CONDUCTOR PREPARATION: Using a proper insulation stripping tool, strip the insulation from the conductor, being careful not to nick the wire strands. Thoroughly clean the conductor by wire brushing until a bright and shiny surface is obtained. All oxides and foreign matter must be removed. NOTE: Do not wire brush tin plated copper conductors. OPERATING INSTRUCTIONS USING THE MHP-1 HAND OPERATED HYDRAULIC PUMP 1. Connect the male half of the hose quick connector to the female half of the quick connector located on the crimping head (see Figure 1). 2. This hand pump can be operated in the horizontal or vertical position when the pump head is pointing down. 3. To extend the cylinder and make a crimp, turn the valve knob clockwise to a closed position, work the handle up and down to build pressure (see Figure 1). 4. To release pressure and retract the movable die turn the valve knob counter clockwise until the die is fully open. CRIMPING A TERMINAL LUG: 1. Place a lug in the movable die making sure the lug is positioned as shown in Figure 4. 2. Close the hand pump valve knob and pump the handle until the dies LOOSELY clamp the lug (see Figure 4). COPYRIGHT 2002 ALL RIGHTS RESERVED 2
DO NOT REMOVE FILLER CAP TOP VIEW OIL LEVEL END VIEW FIGURE 3 3. Insert the conductor into the lug's socket, making sure that the conductor is pushed fully into the lug's crimping area (see Figure 4). 4. Actuate the pump handle and the movable die will start compressing the lug. The crimp is completed when the two dies halves are fully closed. 5. When the die halves are fully closed rotate the valve knob counterclockwise to release and return the movable die to the open position (see Figure 1). CAUTION: IT IS THE OPERATOR'S RESPONSIBILITY TO MAKE SURE THE DIES ARE FULLY CLOSED. FULL DIE CLOSURE IS NECESSARY TO PRODUCE A PROPER CRIMP. CHECKING THE OIL LEVEL AND REFILLING THE OIL RESERVOIR; MHP-1 1. Removed the filler cap shown in Figure 3. The oil level should come to filler hole when the pump is resting on its base and cylinder retracted. 2. Turn the valve handle to release all the pressure and retract the cylinder. Cylinders must always be retracted when checking or adding oil. 3. Clean the area around the filler cap. Remove the filler cap, and position the pump with the head down and the filler hole up. Insert a clean funnel with a filter into the filler hole. 4. Fill the pump with a high-grade hydraulic oil such as Paradene ISO 46(10) part no 40317. 5. Place the pump on its base without the filler cap installed, and let the excess oil drain out (see Figure 3). 6. Replace filler cap. COPYRIGHT 2002 ALL RIGHTS RESERVED 3
STATIONARY DIE HALF CRIMP LUG MOVABLE DIE HALF FIGURE 4 OPERATING INSTRUCTIONS USING THE HPU10 COMPRESSED AIR/HYDRAULIC PUMP. GENERAL: The HPU10 is an air over hydraulic pump capable of delivering (10,000 PSI) of hydraulic pressure. To assure the operator has made an acceptable crimp the unit uses DMC Cycle Control Logic. Once the foot pedal is pressed and the cycle begins, the pump will not stop until it reaches its set point (9000 PSI Factory Set). When the set point is reached the unit will stop pumping and release the system pressure, opening the dies. OPERATING INSTRUCTIONS PUMP SETUP CHECKING THE OIL LEVEL IN THE RESERVOIR HPU10 CAUTION: WHEN ADDING OR CHECKING OIL THE RAM MUST BE IN THE FULLY RETRACTED POSITION (NO PRESSURE IN THE SYSTEM). 1. Position the pump unit so the front panel is facing up (resting on its back). 2. Clean the area around the filler cap and remove the cap located on the left side of the front panel. Wipe the indicating rod free of any oil. 3. Insert rod into the tank (No need to screw down) and determine that the level of oil is at least equal to or above the mark on the indicating rod (see Figure 5). COPYRIGHT 2002 ALL RIGHTS RESERVED 4
EMERGENCY STOP BUTTON FILLER CAP FOOT PRESS AIR INLET FIGURE 5 4. Refill with Paradene ISO 46 (10) Part No. 40317 Drydenoil Corp. Baltimore MD (410) 574-5000 or a suitable oil meeting the above requirements. 5. Connect a clean air supply of 80-120 PSI to the inlet nipple located on the lower right front panel of the pump case. 6. Connect the two foot valve quick couplers to their respective mating connectors located on the lower corner of the front panel. Proper connection is assured by the configuration of the coupler. EMERGENCY STOP BUTTON (ESB): When activating the Emergency Stop Button (located on the top of the unit) the pump will stop pumping and the pressure in the system will be released (see Figure 5). EMERGENCY PROCEDURES 1. NEVER REMOVE THE AIR LINE IN HOPES OF RETRACTING THE DIES. 2. PRESS THE EMERGENCY STOP BUTTON. ANY TIME THE ESB IS ACTUATED THE PUMPING WILL STOP AND THE HYDRAULIC PRESSURE WILL BE RELEASED. EMERGENCY STOP INFORMATION APPEARS ON A LABEL WHICH IS AFFIXED TO THE CASE NEXT TO THE EMERGENCY STOP BUTTON. IF THIS BECOMES LOST OR ILLEGIBLE, CONTACT DMC FOR A REPLACEMENT. COPYRIGHT 2002 ALL RIGHTS RESERVED 5
CRIMPING A TERMINAL LUG: 1. Place a lug with the conductor fully inserted into the wire barrel as shown (see Figure 4). 2. Actuate the foot pedal and the movable die will start compressing the lug. The crimp is completed when the HPU10 pump cycles and opens the dies fully. 3. For additional crimping instructions refer to the guidelines supplied by the terminal manufacturer, crimp die set manufacturer, or the system manager. Daniels Manufacturing Corporation offers complete refurbishing and recalibration services. DMC specially engineers and manufacturers 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 Daniels Manufacturing Corporation is not liable for consequential or special damages of 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 their employees in the proper and safe use of such products. LIMITED WARRANTY DMC ( Daniels Manufacturing Corporation) warrants each new product sold by it to be free from defects in material and workmanship under normal use and service. DMC's obligation under this warranty is limited to the free correction or, at DMC's option, the refund of the purchase price of any such product which proves defective in normal service within ninety (90) days after delivery to the first user, provided that the product is returned to DMC with all transportation charges prepaid and which shall appear to DMC's satisfaction, after DMC's inspection, to have been defective in material or workmanship, it been 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 warranty is in lieu of all other warranties express or implied. No warranty, express or implied, is made or authorize to be made or assumed with respect to products of Daniels Manufacturing Corporation other than those herein set forth. COPYRIGHT 2002 ALL RIGHTS RESERVED 6