Ilsco IDT-12-N User manual

INSTRUCTION MANUAL
99945282 REV 6 © 2009 Ilsco Corporation Q.F.5.4.55 2/09
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
IDT-12-N
Hydraulic Crimping Tool

Ilsco Corporation 2 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
KEEP THIS MANUAL
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
Warranty and Service ..................................................... 2
Important Safety Instructions ..................................... 3–4
Identication................................................................... 5
Specications................................................................. 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exibility.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.

Ilsco Corporation 3 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
IMPORTANT SAFETY INFORMATION
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.
Weareyeprotectionwhenoperating
or servicing this tool.
Failuretoweareyeprotectioncould
result in serious eye injury from ying
debris or hydraulic oil.
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.
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,denedbelow,
indicates the severity of the hazard. The message
afterthesignalwordprovidesinformationfor
preventing or avoiding the hazard.
Immediatehazardswhich,ifnotavoided,WILLresult
in severe injury or death.
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.

Ilsco Corporation 4 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
IMPORTANT SAFETY INFORMATION
An incomplete crimp can cause a re.
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 rm grip on both handles during opera-
tion. 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 5 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
Identification
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in3)
Crimping Capacities
Crimping Range
Copper Connectors .................................. 25 mm2to 500 mm2(#4AWGto1000Kcmil)
Aluminum Connectors .............................. 16mm2to 500 mm2(#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.
Movable
Pin Unit
Release
Trigger
Ram Die
Die Head

Ilsco Corporation 6 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
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.
Weareyeprotectionwhenoperating
or servicing this tool.
Failuretoweareyeprotectioncould
result in serious eye injury from ying
debris or hydraulic oil.
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.
An incomplete crimp can cause a re.
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.

Ilsco Corporation 7 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
Operation (cont’d)
Preparation
1. Selectapropersizeandtypeofconnectortocorre-
spond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.
Direction of Ram Travel
Tang
3. Ifopen,closethedieheadandpushinthe
movable pin unit. Make sure the movable pin is fully
engaged.
4. Alignthetoolwiththealignmentmark(forlugs)or
centerstop(forsleeves)asshown.
OUTERMOST
BLADE OF DIE HEAD
LUG
ALIGNMENT
MARK
LONGER LUG
TANG
OUTERMOST
BLADE OF RAM DIE
LUG
ALIGNMENT
MARK
SHORTER LUG
TANG
OUTERMOST
BLADE OF DIE HEAD
CENTER
STOP
SLEEVE
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 specied 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 8 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
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.
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tsovertheslugandtheNOGO
slotdoesnot,thepressureiswithinthespecied
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crimp-
ing pressure is too high. Send the crimping tool to
Ilsco.
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
rst.
GO Gauge NO GO Gauge
Check Point
(center depression of the three depression side)
6. Discard the slugs.

Ilsco Corporation 9 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
Troubleshooting
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uid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overlled. Referto“AirPurgingandOilFillingProcedure.”
Internal binding. 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llprocedure. Referto“AirPurgingandOilFillingProcedure.”
Loose or missing reservoir plug. Replace plug.
Reservoir damaged. Replace reservoir.
 ReservoirmissingO-ring. ReplaceO-ring.
 DamagedO-ringonlowpressure ReturntooltoIlsco.
injector.
Probable CauseProblem Probable Remedy

Ilsco Corporation 10 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
Air Purging and Oil Filling Procedure
FillthereservoirwithExxonUnivis®J26 all temperature
hydraulic oil only.
Donotllthehydraulicreservoirwithanyothertype
ofuid(suchasbrakeuid,glycerine,castoroil,etc.).
Fillingthereservoirwithanythingotherthanhydraulic
uidwilldamagethetoolandvoidthewarranty.
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).
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,llthereservoiruntilitoverows.
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.
1. Clampthetoolintoavisewithjawprotectorssothe
handlesareupward,asshown.
5. Unscrewthereservoirhandlefromthecrimping
tool.Removetheplug(25)fromthereservoir.
6. Retract the ram fully.
7. Addoiluntilthereservoiroverows.
Vise with Jaw
Protectors
Rubber
Plug (26)
Remove
set screw (27).
Reservoir
Plug
(25)

Ilsco Corporation 11 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
Illustration
7
17
29
5
4
2
3
23
24
25
22
16 21
27
26
1
18
19
20
28
15
16
14
13*
10
11
12
8
15
6
9
Torque cap screws (13) to 20.3 Nm (15 ft-lb).

Ilsco Corporation 12 4730MadisonRd.•Cincinnati,OH45227-1426•800/776-9775
IDT-12-N Hydraulic Crimping Tool
Parts List
Key Part No. Description Qty
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: [email protected]•Website: http://www.ilsco.com
 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at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identication .....................................................................2
Printed in the USA