SERVICE AND
OPERATION
MANUAL
SEE
PAGE
i
FOR
IMPORTANT
INFORMATION
CONCERNING
LIMITED WARRANTY. AND LIMITATION OF LIABILITY.
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HC134
4-INDENT DIE-LESS
CRIMP TOOL
DANIELS MANUFACTURING CORP.
ORLANDO, FLORIDA
CAGE 11851
DATE: 12/01
REVISION: C
COPYRIGHTC 2001
ALL RIGHTS RESERVED
DANIELS MANUFACTURING CORP.
526 THORPE
ROAD
ORLANDO, FL 32824
PHONE (407) 655-6161
FAX (40'7) 855-6884
WWW.DMCTOOLS.COM
E-MAIL: DMC@DMCTOOLS.COM
HC134-DB
INVALIDATION OF LIMITED WARRAN1Y
This repair manual is provided to those owners of Daniels Manufacturing Corp. (DMC)
products whe have elected to conduct in-house repairs of such products and who
thereby consent to waive rights which they otherwise might have had under the
DMC Limited Warranty applicable to such products.
DMC provides complete repair and maintenance service for all of its products. Owners
of DMC products are warned that any tampering, including partial or complete disassembly
of the product will invalidate the Limited Warranty applicable to said product.
(a) LIMITED WARRANTY: DMC warrants each new product sold by DMC to be free from
defects in material and workmanship under normal use and service. The sole obligation
and liability of DMC under this warranty is limited to, at its option, the repair of,
the refund of the purchase price of, or the replacement at its factory of any such
product which proves defective within 90 days after delivery to the first end user, and
is found to be defective in material or workmanship by DMC inspection.
(b) In no case shall this warranty be effective unless delivery to the end user occurs within
180 days after delivery by DMC to the original purchaser. and written notice of any defect
shall have been given to DMC within 30 days from the date such defect is first discovered.
(c) Products for warranty consideration shall be returned with all transportation charges prepaid
to DMC. Products repaired or replaced under this limited warranty are warranted for the
unexpired portion of the original warranty and shall be returned F.O.B. factory, Orlando,
Florida.
(d) DMC disclaims any liability whether under this warranty or otherwise for any failure of its
products which is caused, in whole or in part, by the use in or with that product of
component parts net manufactured by DMC, er if said failure has, in the opinion of DMC
inspection, been caused by tampering, misuse, neglect, improper storage, normal wear and
tear or improper operation.
(e) The terms of this limited warranty are the sole and exclusive warranty terms that shall have
any force and effect in this order and such terms are in lieu of all other warranties
expressed or implied including, but not limited to the implied warranties of or merchantabilit y
and fitness for a particular purpose, which are herewith expressly excluded. NO WARRANlY,
EXPRESS OR IMPLIED, IS MADE OR AUTHORIZED TO BE MADE OR ASSUMED WITH RESPECT TO
THE PRODUCTS OF DMC OTHER THAT HEREIN SET FORTH.
(aa) LIMIT ATION OF LIABILITY; other than the liability set forth in the above expressed warranty
applicable to the products sold to the purchaser, DMC SHALL NOT BE LIABLE FDR
CONSEQUENTIAL. INCIDENTAL. SPECIAL. OR OTHER lYPES OF DAMAGES AND EXPRESSLY
EXCLUDES AND DISCLAIMS SUCH DAMAGES RESULTING FROM OR CAUSED BY THE USE,
OPERATION, FAILURE, MALEFACTION OR DEFECTS OF ANY PRODUCTS SOLD TO THE PURCHASER
AND THROUGH PURCHASER TO ANY OTHER PURCHASERS OR END USERS UNDER THIS OR ANY
OTHER ORDER, IT BEING UNDERSTOOD THAT THE PRODUCTS SOLD HEREUNDER ARE NOT
CONSUMER PRODUCTS.
Orange County, Florida, U.S.A. shall be the proper venue for any action or claim arising
because of any alleged defect of any product, service or information manufactured or
supplied by DMC. In the event of litigation, Florida law shall govern and DMC, if it prevails,
in whole or in part, shall be entitled to reasonable attorney's fees, witness fees, and
court costs.
LIMITED WARRANTY AND LIMITATION OF LIABILITY
TABLE OF CONTENTS
Warranty
GENERAL OPERATION AND MAINTENANCE:
Warning .....................................................................................................
Cold Weather Note ...................................................................................
Storage .....................................................................................................
CAUTION: Crimping Small Diameter Splices and Terminals ...................
Preventative Maintenance Tool Requirements .........................................
Care of Hydraulic Tools ...........................................................................
Operating Instructions .. ..........................................................................
Conductor Preparation .............................................................................
Crimping a Sleeve Conductor ..................................................................
Removing a Spliced Cable .......................................................................
PREVENTATIVE MAINT ENANCE:
Cleaning and Lubricating Tool Head .......................................................
Checking System Pressure ..... .................................................................
Checking Pump Oil Level .........................................................................
Loss of Hydraulic Oil ...............................................................................
PREVENTATIVE MAINTENANCE PROCEDURES:
Lubricating Tool Head ..............................................................................
Tool Head Disassembly ............................................................................
Tool Head Assembly .................................................................................
Addition of Hydraulic Oil ..........................................................................
Replacement of Oil Plunger 0-Ring .......................................................
Inspection/Replacement of Pressure Adjusting Valve .............................
Installation of PSI Valve ..........................................................................
Adjustment of Pump System Pressure ...................................................
Removal of Ram Lip Seal .......................................................................
Installation of Ram Lip Seal ...................................................................
Removal of Ram Return Spring ..............................................................
Service of Inlet/Outlet Ball Valves ..........................................................
Removal of Bypass Valve Ball ................................................................
lnstalk1tion of Bypass Valve Ball .............................................................
Removal of Pump Piston Seals ..............................................................
Installation of Pump Piston Seals ..........................................................
Removal of Relief Rod ............................................................................
Replacement of Relief Rod Seal .............................................................
Adjustment of Relief Rod Actuator .........................................................
Inspection of Relief Valve Ball ................................................................
Replacement of Gauge Adaptor Seals ....................................................
Assembly of Gauge Adaptor ....................................................................
Installation of Relief Valve Ball ..............................................................
MAINTENANCE Tl PS:
Lubrication Recommendations .................................................................
0-Ring Installation ...................................................................................
Reseating of Bal I Valve Seats ................................................................
Pump Assembly Breakdown .....................................................................
Head Assembly Breakdown ... .................................................................
Troubleshooting, Diagnosis and Remedies ..............................................
6
B
8
8
10
11
11
12
13
13
15
15
16
16
16
1B
18
19
19
20
20
20
20
6
6
6
6
2
2
Inside Front Cover
2
2
3
4
4
4
5
2
21/22
21
19
23/24
25
26/28
11
HINGE PIN
BRIDGE LOCKING PIN
4 INDENTERS
(1 FIXED)
(3 MOVABLE)
GAUGE
ADAPTOR½
FITTING
RELEASE ROD
0
\--½½ HANDLE RELEASE PIN
PUMPING
STROKE
OR
RETRACT
MANUAL
ADVANCE
MANUAL
RETRACT
ADVANCE HANDLE
ROTATE AND
DEPRESS HANDLE
TO RETRACT
INDENTERS
PUMP HANDLE
AND
RELEASE HANDLE
FIGURE 1
1 OF 28
GENERAL OPERATION AND MAINTENANCE
WARNING:
The fiberglass handles end neoprene grips are NOT designed to protect the operator
1
In ½ HOT" llne work I
COLD WEATHER N DTE:
This tool and tool kit is supplied with Drydene Paradene 32AW hydraulic oil. For
operation below 20"F (-TC), refill reservoir with Drydene 22AW hydraulic oil. In cold
weather and non-use, 0-Ring seal sticking may cause non-pumping. rotate the
advance handle clockwise to advance the indenters and free any sticking 0-Rings.
STORAGE:
When tool is to be stored for any extended period of time, lhe tool should be
pumped up approximately every three (3) weeks to keep the 0-Rings and seals lubricated.
The tool should also be stored with the indenters in the fully open position.
CAUTION: CRIMPING SMALL DIAMETERS SPLICES AND TERMINALS:
Extra care should be taken when positioning and crimping small diameter splices and
terminals. These items can become lodged between the tool head and the indenter
system (see Figure 4 ).
GENERAL MAINTENANCE:
The HC134 is a hydraulic crimp tool which requires well trained, experienced personnel
having a clean work area equipped with adequate tools for major repairs, adjustments
or maintenance.
PREVENTATIVE MAINTENANCE TOOL REQUIREMENTS
1. Hydraulic oil: Drydene Oil Co. Paradene hydraulic oil 32AW or 22AW depending upon
ambient temperature (see Cold Weather Note). DO NOT USE BRAKE FLUID!
2. DMC part number HP1036-RK Repair Kit.
3. An environmentally approved degreasing solvent.
4. Bench type vise having a 4" minimum opening and soft jaws.
5. Hex wrench set.
6. Pin punch set.
7. 1
standard (flat blade) screwdriver.
El. 9/16·,
3/a"
and 5/8• open-end wrenches.
9. Lightweight hammer.
1 0. Oil catch pan.
11. DMC part number HPG1 Pressure Gauge.
12. Truarc® series 5133-25 E-Ring applicator.
o"
DANIELS MANUFACTURING CORP. OFFERS A COMPLETE REFURBISHING AND
REC.ALIBR.ATION SERVICE. CONTACT CUSTOMER SERVICE.
DMC ALSO SPECIALL ENGINEERS AND MANUFACTURES COMPLETE TOOL KITS TO SATISFY
SATISFY INDMDUAL CUSTOMER REQUIREMENTS, SUCH AS TOTAL SUPPORT, GENERAL
SHOP MAINTENANCE OR PRODUCTION, ON BOARD SHIP AND VEHICLE SERVICE, ETC.
PHONE (407) 855-6161
FAX (407) 855-68B4 E-MAIL: DMC@DMCTOOLS.COM
2. DF 28
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