DMC PH1005 User manual
SAFETY OPERATION MANUAL
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COPYRIGHT© 2001 ALL RIGHTS RESERVED 12/01 REV. A FILE #: SOM0021 DOC. #: PH1005-SOM
DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA
INTRODUCTION
The PH1005 Power 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. Undernocircumstancesshouldthecrimpingtoolbeattachedtoanycontrolboxorpowersystemotherthan
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’sresponsibility to properlytrain and instructall tool operatorsin the properuse of thistool.
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.
PREPARING TOOL FOR OPERATION (see Figure 1)
The PH1005 Power Crimp Tool consists of the PHMT1005 Crimping Tool, PHRPU4 Remote Power Unit, PHFV-
3 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 as-
semble the separate parts:
1. ConnectthehydraulichosefromthePHMT1005CrimpingToolinto the hydraulic quickdisconnectonthefront
panelof the PHRPU4RemotePowerUnitby pushing backonthelockingring of thehydraulicquickdisconnect
andpluggingthe male part of the hydraulic hose into the provided area. The operator willrealizetheconnection
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. Connectthe shop air supply to the airquickdisconnectbypullingbackon the air hose coupling and insertingthe
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 BenchMountis supplied,attachittothePHMT1005Crimping Toolbythreading themalethreadof the
benchmount into the female thread on the tool. Adjusttool to appropriate working position, and lock handleon
bench mount.
EMERGENCY STOP BUTTON
ThePHRPU4 Remote PowerUnitisconfiguredwith an EmergencyStopButton.Bypressing this buttonatanytime
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
PH1005
POWER CRIMP TOOL
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SAFETY OPERATION MANUAL
12/01 REV. A FILE #: SOM0021 DOC. #: PH1005-SOMCOPYRIGHT© 2001 ALL RIGHTS RESERVED
DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA
allowed to release.
Tool Head Positioning (see Figure 2):
Thetoolheadon the PH1005 Crimping Tool mayberotatedto any selectable position relative totheactuatorthat an
operatormight prefer. To select or changethe head position, loosen thehead position holding screw sothe head can
be turned by hand and rotate head to selected position, then tighten screw.
TOOL OPERATION:
After the PH1005 tool has been assembled with the dies in their proper location, the tool is ready 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.
FIGURE 1
PHRPU4
EMERGENCY STOP
BUTTON
INPUT AIR
QUICK DISCONNECT
SINGLE COUPLING CONTROL
DUAL COUPLING CONTROL
HYDRAULIC QUICK
DISCONNECT
AIR BLEED
(ACTUATOR)
BM-2
(OPTIONAL)
PHFV-3
(OPTIONAL)
PHMT1005
FIGURE 2
HYDRAULIC FLUID
FILL HOLE
AIR BLEED HOLE (SEAL HOLE
WITH FINGER TO ACTIVATE
TOOL)
HEAD POSITIONING HOLDING SCREW
PHMT1005
CRIMP TOOL
PRESS HERE TO LOAD AND UNLOAD SPLICE
SAFETY OPERATION MANUAL
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COPYRIGHT© 2001 ALL RIGHTS RESERVED 12/01 REV. A FILE #: SOM0021 DOC. #: PH1005-SOM
DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA
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 intensi-
fier, 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,
coverthe bottom with about1/4"ofISO46AWhydraulicfluid. Reassemble cover, align holesandtightendown
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, plug in the air supply to the fitting provided on the rear of the
FIGURE 3
TO PHFV-3 FOOT PRESS
SINGLE COUPLING CONTROL
EMERGENCY STOP
BUTTON
PHRPU4 REMOTE POWER UNIT
PHVG CONNECTION
(ADAPTOR)
AIR SUPPLY
PHVG HYDRAULIC
FILL BOWL
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SAFETY OPERATION MANUAL
12/01 REV. A FILE #: SOM0021 DOC. #: PH1005-SOMCOPYRIGHT© 2001 ALL RIGHTS RESERVED
DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA
vacuum generator. As a vacuum is formed, air bubbles will pull through the oil in the bowl and the fluid level
willrise slightly. Continue toallow the vacuumgenerator to "run"until there areno noticeable bubblesflowing
through the system, or the flow of bubbles is at minimum. Unplug the air supply slowly and watch as the level
offluidinthebowllowers. Afterwaitingaboutfiveseconds,thetoolhosecanbedisconnectedfromthesystem.
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.Whentheoillevelnolongerlowers(aboutfiveseconds)thegenerator/adaptormaybeuncoupled
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.If fluid, otherthan 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 proce-
dure 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" gage end into appropriate 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.
SAFETY OPERATION MANUAL
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COPYRIGHT© 2001 ALL RIGHTS RESERVED 12/01 REV. A FILE #: SOM0021 DOC. #: PH1005-SOM
DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA
GAGING DIMENSIONS FOR PH1005:
.079
±.003
.057
±.003
FIGURE 4
.049
±.003
WHEN CHECKING GAGING
DIMENSIONS, HOLD JAWS
TOGETHER TO INSURE A
FULLY CLOSED POSITION.
CRIMP
CAVITY GAGE
P/N
G739
G740
G741
22-16
16-14
12-10
"GO"
DIM A
.046
.054
.076
"NO-GO"
DIM B
.052
.060
.082
GREEN "GO" RED "NO-GO"
AB
GAGE
FIGURE 5
PH1005 SYSTEM COMPONENTS:
PART NUMBER
PHMT1005
PHRPU4
PHVG
DESCRIPTION
CRIMPING TOOL
REMOTE POWER UNIT
VACUUM GENERATOR
QTY
1
1
1
DESCRIPTION
BENCH MOUNT
FOOT PRESS
POWER TOOL SYSTEM ACCESSORIES:
PART NUMBER
BM-2
PHFV-3
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 ofthepotentialrisk involved. These signs 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 equip-
ment and be aware of the risks involved. While using the tool, it is important to be alert and avoid distractions.
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SAFETY OPERATION MANUAL
12/01 REV. A FILE #: SOM0021 DOC. #: PH1005-SOMCOPYRIGHT© 2001 ALL RIGHTS RESERVED
DANIELS MANUFACTURING CORP. 526 THORPE ROAD, ORLANDO, FL 32824, USA
LIMITATION OF LIABILITY/LIMITED WARRANTY*
DMC (DANIELS MANUFACTURING CORP.) IS NOT LIABLE FOR CONSEQUENTIAL
ORSPECIAL DAMAGES OF ANY NATUREOR KIND RESULTINGFROM THE USE,OR MISUSE, OF
ANY OF ITS PRODUCTS. OWNERS AND USERS OF DMC PRODUCTS ASSUME FULL RESPONSI-
BILITY FOR INSTRUCTING OPERATORS IN THE PROPER AND SAFE USE OF SUCH PRODUCTS.
OPERATORSASSUMEFULLRESPONSIBILITYFOROPERATINGDMCPRODUCTSINASAFEMAN-
NER 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 undernormaluseandservice. DMC's obligation underthiswarrantyislimited to the
freecorrection or, at DMC's option,the refund of the purchaseprice of any such productwhich proves defective
in normal service within ninety (90) days after delivery to the first user, provided that the product is returned to
DMCwithalltransportationcharges prepaid and which shall appear to DMC's satisfaction,afterDMC'sinspec-
tion, to have been defective in material or workmanship, it being understood that DMC products are not con-
sumer 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 a particular purpose and warranties of safe 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
FINGER FREE AREAS
EMERGENCY STOP
DISCONNECT FRDISCONNECT FR
DISCONNECT FRDISCONNECT FR
DISCONNECT FROMOM
OMOM
OM AIR SUPPLAIR SUPPL
AIR SUPPLAIR SUPPL
AIR SUPPLYY
YY
Y
BEFOREBEFORE
BEFOREBEFORE
BEFORE AA
AA
ATTEMPTINGTTEMPTING
TTEMPTINGTTEMPTING
TTEMPTING TT
TT
TOO
OO
OADJUSTADJUST
ADJUSTADJUST
ADJUST
TT
TT
TOOL OR DIESOOL OR DIES
OOL OR DIESOOL OR DIES
OOL OR DIES..
..
.
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.
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