Ilsco ND-58 User manual

INSTRUCTION MANUAL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
ND-58 and ND-60
Mechanical Crimping Tools
999 4935.0 © 2003 Ilsco Corporation 7/03

Ilsco Corporation 24730 Madison Rd. • Cincinnati, OH 45227-1426 • 800/776-9775
ND-58 and ND-60 Mechanical CrimpingTools
All specifications are nominal and may change as design improve-
ments occur. Ilsco shall not be liable for damages resulting from
misapplication or misuse of its products.
KEEPTHIS MANUAL
Description
The ND-58 and ND-60 Mechanical Crimping Tools are
hand-operated tools that use permanent die grooves and/
or insertable W-type dies. They install a full range of
connectors including service entrance, splices, terminals,
stacking lugs, street light, stirrup, and repair sleeves.
The tools have two permanent die grooves, “O” or “BG”
and “D3” for distribution tap connectors. The “D3” groove
also serves as a seat for die inserts to install additional
connectors. The die inserts snap into a permanent “D3”
die holder groove easily with one hand, and are secured
with the spring-loaded, positive lock, die retainer buttons.
The tools incorporate an over center toggle action
mechanism, allowing for easy crimping operations and
field adjustability.
For use on:
• Copper taps from #10 solid to #2/0 stranded
• Aluminum/ACSR taps from #14 solid to #4/0 ACSR
• Stirrups from #6 AWG to #4/0 ACSR
• Copper and aluminum code conductor connectors
from #6 AWG to #4/0 stranded
• Overhead full tension deadend, full and non-tension
splices and terminals from #10 stranded to #4/0 ACSR
• 5/8" and .840" service entrance sleeves
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 tools:
ND-58 and ND-60 Mechanical Crimping Tools
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 instruc-
tions and operating procedures are not followed. Contact
Ilsco for all warranty and service issues at 800-776-9775.
Electric shock hazard:
This tool is not insulated. Do not use
on live circuits.
Contact with live circuits can result in
severe injury or death.
An incomplete crimp can cause a fire.
Use proper connector and cable combinations.
Improper combinations can result in an incomplete
crimp.
Failure to observe this warning can result in severe
injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying debris.
• This tool is intended for two-handed operation.
Maintain a firm grip on both handles when using
this tool.
• Inspect tool before use. If any parts are worn or
damaged, send the tool to an authorized Ilsco
service center.
• Do not perform any service or maintenance other
than as described in this manual.
• Do not exceed the rated capacity of this tool.
Failure to observe these precautions can result in
injury or property damage.
IMPORTANT SAFETY INFORMATION

Ilsco Corporation 34730 Madison Rd. • Cincinnati, OH 45227-1426 • 800/776-9775
ND-58 and ND-60 Mechanical CrimpingTools
Specifications
Crimp Force Developed .......................4091 kg (9000 lb)
Weight (tool only) ..........................................2.7 kg (6 lb)
Operation
Die Selection
• For the ND-60, the upper opening is a “BG” die.
• For the ND-58, the upper opening is an “O” die.
• For both the ND-58 and ND-60 tools, the lower
opening is a “D3” die.
• Interchangeable dies may be used in the lower die
opening. Dies that may be used include:
— Ilsco ND series
— Greenlee KD6 series
— Burndy W and X series
— Huskie HT58 series
— Panduit CD-2001 series
— Other industry W-type dies
Operation Procedure
1. Select the proper dies for the connector to be
crimped.
2. Install dies in jaws making certain that they are
properly secured by the spring-loaded, positive lock,
die buttons.
3. Insert conductor into the connector and align the tool
and die on the connector. Start in the center for
splices and “H” frames, and on the end, nearest the
pad, for terminals.
4. Operate the tool by closing, and allowing, the handle
butt/stop blocks to touch. Normally a “pop” will be
heard as the tool goes over center after the crimp is
made.
5. Continue crimping the connector until the correct
number of crimps have been completed. Work from
the center to the outer edges for splices and “H”
frame connectors, alternating sides if possible, for
the best compression connection.
6. Reposition tool for next crimp, if required. Unless
non-bowing dies are used, it is recommended that
the tool be rotated 90°for each adjacent crimp on
large splice connections.
To help minimize hand and arm fatigue and
perceived handle force during use, hold the
crimping tool with your hands at the end of the
handles.
Inspection and Adjustment
Check tools periodically for correct adjustment. As with
any tool, a slight amount of wear may occur over time.
This wear may be corrected by readjusting the tool as
follows:
1. Remove any die inserts from the tool and make sure
the jaw tips are free of dirt, etc.
2. Open tool and close handles until jaw tips just touch.
DO NOT CLOSE HANDLES COMPLETELY!
3. Check that the index marks (red grooves) on the
toggle link and frame line up.
Adjusting
Set Screw
Locking
Set Screw
4. If the marks line up, the tool is in proper adjustment.
5. If the marks do not line up, loosen the locking set
screw using a 1/4" (6.4 mm) hex key, and then turn
the adjustment screw clockwise or counterclockwise
until the marks line up.
6. Tighten the locking set screw securely; the tool is
now properly adjusted and ready for use.
Correct Adjustment
required

Ilsco Corporation 44730 Madison Rd. • Cincinnati, OH 45227-1426 • 800/776-9775
ND-58 and ND-60 Mechanical CrimpingTools
Illustration and Parts List
Key Description Qty
1 Jaw (ND-60)......................................................................... 2
Jaw (ND-58)......................................................................... 2
2 Bushing, oil free ................................................................... 3
3 Spring, ø 6 x L10.8 .............................................................. 2
4 Pin, push .............................................................................. 2
5 Nut ....................................................................................... 2
6 Spindle ................................................................................. 1
7 Link ...................................................................................... 2
8 Bolt, shoulder ....................................................................... 2
9 Nut ....................................................................................... 2
10 Head, handle (A).................................................................. 1
11 Head, handle (B).................................................................. 1
12 Toggle .................................................................................. 1
13 Pin, drive .............................................................................. 1
14 Bolt, shoulder ....................................................................... 3
15 Nut ....................................................................................... 3
16 Screw ................................................................................... 1
17 Screw ................................................................................... 1
18 Tube, shrinkage ................................................................... 2
Repair Kits
500 2793.0 Kit, blade replacement (ND-58);
includes two of items 1–5, 7–9, and one of item 6
500 2794.8 Kit, blade replacement (ND-60);
includes two of items 1–5, 7–9, and one of item 6
500 2137.0 Kit, plate replacement; includes two of items 7–9
500 2148.6 Kit, handle-adjusting replacement;
includes one of items 10, 12–18
500 2149.4 Kit, bolt-handle replacement; includes three of items 2, 14, 15
500 2150.8 Kit, pin-die replacement; includes two of items 3–5
500 2152.4 Kit, handle replacement;
includes one of items 11, 18, and two of items 14, 15
500 2151.6 Kit, screw-set; includes one of items 16, 17
15
15
2
17
16
9
9
714
15
1
3
4
5
8
3
4
8
7
6
5
13
2
12
14
14
1
18
18
10
2
11
Printed in the USA
U.S.TECHNICAL SUPPORT
1-800-776-9775
Ilsco Corporation • 4730 Madison Road, Cincinnati, Ohio 45227-1426
Phone [phone] • Fax [phone]
E-mail: [email protected] • Web site: http://www.ilsco.com