KUDOS UB-412 Maintenance and service guide

.
KuDos Industrial Inc. U.S.A.
Safety Operating & Maintenance Instructions
Hydraulic Hand Compression Crimper
UB-412
Version: 2006/07
Hydraulic Hand Compression Crimpers comply with
ISO 9001:2000. We guarantee our qualities and services.
ATTENTION!
Safety Operating & Maintenance Instructions must be followed.

Table of Contents
Ϭʳ Table of Contents ΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 1
Ϭʳ Safety Instructions’ΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 2
Ϭʳ Product DescriptionΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 3
Ϭʳ Characters & FunctionsΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 4
Ϭʳ Operation Manual ΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 5
Ϭʳ Trouble – ShootingΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 8
Ϭʳ Maintenance’ΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 9
Ϭʳ Limited WarrantyΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 10
Ϭʳ Diagram of Parts & ComponentsΗΗΗΗΗΗΗΗΗΗ 11
Ϭʳ Table of Parts & ComponentsΗΗΗΗΗΗΗΗΗΗΗ 12
Ϭʳ DiesΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 13
Ϭʳ Operation Instructions ΗΗΗΗΗΗΗΗΗΗΗΗΗΗ 14
Ϭʳ Manufacture & Quality Certificate
Page: 1 KuDos Industrial Inc. U.S.A.

Operation Instructions
ϮDirection of CompressionΚ
Single-sided / Outward
ϮDirection of CompressionΚ
Outward
KuDos Industrial Inc. U.S.A. Page: 14

Dies
ϮHex DiesΰFor Copper Lugsα
Unit: mm
Die No. A B C
CU-16
7.20 3.12 14.00
CU-25
8.43 3.67 14.00
CU-35
10.00 4.33 16.00
CU-50
11.60 5.02 16.00
CU-70
13.70 5.95 15.60
CU-95
15.90 6.85 15.70
CU-120
17.98 7.79 16.00
CU-150
20.10 8.70 15.00
CU-185
22.33 9.67 14.00
CU-240
25.43 11.01 13.00
CU-300
28.44 12.32 11.20
CU-400
30.00 14.55 11.50
ϮHex DiesΰFor Solderless Terminalsα
Unit: mm
Die No. A B C
CU-8-14
7.40 3.50 8.00
CU-22
8.80 4.30 10.00
CU-38
11.50 5.40 11.50
CU-60-70
13.40 6.00 15.00
CU-80
15.00 6.75 18.00
CU-100
18.00 8.00 15.00
CU-150-180
21.00 9.10 13.00
CU-200
28.44 12.32 11.20
CU-325
30.00 14.56 11.50
Page: 13 KuDos Industrial Inc. U.S.A.

Safety Instructions
ϮFollow instructions to assure safety.
Thank you for using products. This handbook must be read carefully
prior to operating the product. Special attentions should be paid to the section
"Safety Instructions". Damages and injuries caused by improper uses of the
product are NOT included in our warranty. We would like to remind you to work
safely and keep this handbook on hand.
Goggles are recommended
during operation of the product.
Safety Operating & Maintenance
Instructions must be read carefully
prior to operating the product.
Keep hands off the compression
section while operating the
product.
This product is NOT an insulator.
Proper equipments should be
used to avoid electric shock.
ATTENTION
WARNING
KuDos Industrial Inc. U.S.A. Page: 2

Product Description
Ϯ
ϮϮ
ϮSubassemblies
Piston Set
C-Head
Cylinder Body
Moving Handle
Fixed Handle
Locking Pin
Locking Pin
Relief Valve
Page: 3 KuDos Industrial Inc. U.S.A.

Table of Parts & Components
No.
Q'ty
Part
No.
Q'ty
Part
1
1
Cylinder Body
44
1
Arresting Pin
2 1 Dust Seal 45 2 Spring Pin
3 1 O-Ring 46 1 Socket Head Cap Screw
4 1 Locating Screw 47 1 Guide Block
5 1 Release Lever 48 1 Dust Seal
6 1 O-Ring 49 3 Spring Washer
7 1 Compression Spring 50 1 Cap
8 2 Valve Screw 51 1 Spring Pin
9 2 Compression Spring 52 4 Bushing
10 2 Ball 53 1 Conical Pin
11 1 Compression Spring 54 1 Torsional Spring
12 1 Ball 55 1 Release Pin
13 1 Screw 56 1 FRP Pipe
14 2 Back Up Ring 57 1 Guide Bult
15 2 O-Ring 58 1 Insulation Cap
16 1 Compression Spring 59 1 Robber Handle Tube
17 3 Ball 60 1 Extention Tube
18 1 Set Screw 61 1 FRP Pipe
19 1 Ball 62 1 Spring Pin
20 1 Set Screw 63 1 Insulation Tube
21 1 64 1 Rubber Handle Tube
22 1 65 2 Socket Head Cap Screw
23 1 66 2 Crescent
24 1 67 1 Hinge Pin
25 1 68 1 Pumping Piston
26 1
Relief Valve Set
69 1 Arresting Pin
27 2 O-Ring 70 1 Oil Bag
28 1 O-Ring 71 1 Magnetic Bar
29 1 Solid Filter 72 1 Bung
30 1 Push-In Fastener 73 1 Main Piston
31 2 Compression Spring 74 1 Arresting Pin
32 1 Screw 75 1 Spring
33 1 Ball Seat 76 1 Compression Spring
34 1 Screw 77 1 Locating Pin
35 1 Insulation Cover 78 1 Back Up Ring
36 1 Hook Spring 79 1 O-Ring
37 1 O-Ring 80 1 Spring Rod
38 1 Funnel 81 1 Compression Spring Support
39 1 C Head 82 1 Inverse Ring
40 1 Spring Pin 83 1 Spring Pin
41 1 Locating Ring 84 1 Compression Spring
42 1 Stop Screw 85 1 O-Ring
43 1 Compression Spring 86 1 Back Up Ring
KuDos Industrial Inc. U.S.A. Page: 12

Diagram of Parts & Components
Page: 11 KuDos Industrial Inc. U.S.A.

Characters & Functions
ϭC-Head open : 32 mm
ϭMax. compression : 32 mmФcopper lugs
ϭMax. operating pressure : 700 bar / 10,000 psi
ϭExternal adjustable relief valve
ϭPressure relief valve for overload protection
ϭʳ Automatic low-/high-pressure conversion with rapid/mild operating
Motion
ϭʳ 180rotating head
Specifications
ϮItem Hydraulic Hand Compression Crimper
ϮModel No. UB-412
ϮMax. Pressure 700 bar / 10,000 psi
ϮMax. Output 12 Tons
ϮDimensions 590mm(L)150mm(W)70mm(H)
ϮNet Weight 4.4 kgs
ϮGross Weight 7.0 kgs
ϮAccessories KuDos plastic carrying case / Dies not included
KuDos Industrial Inc. U.S.A. Page: 4

Operation Manual - I
ϮMake sure all parts of the product are clean and rustless.
ϮNo leakage occurs while the product is not operated.
Ϯʳ No leakage occurs (either at low pressures or at high pressures)
while the product is tested without cables.
Ϯʳ Hydraulic pressure should be able to reach 700 bar / 10,000 psi
while tested without cables.
Ϯʳ Operations without dies in place are strictly prohibited.
Ϯʳ Check the cleanness of the product before use.
Ϯʳ Make sure no loose parts exist before use.
Ϯʳ Always use dies which fit the specifications. No overloaded com-
pression is allowed.
Ϯʳ Stop operating immediately in case of any abnormalities.
ΰPlease refer to "Page 8 : Trouble-Shooting"α
1. Compression of lugs cannot be implemented.
2. Moving handle is stuck or is unable to rotate to release the pressure.
3. Dies can not be set in place or can not be removed.
4. The piston is stuck or is unable to retract after operation.
Ϯʳ Clean the product and dies after use. Apply rust preventive oil to the
product and dies before putting back to the carrying case.
Page: 5 KuDos Industrial Inc. U.S.A.

Limited Warranty
Ϯʳ Limited warranty of KuDos® goods are valid for a period of one year
from the date of purchase.
Ϯʳ Receipt and warranty card are required for warranty services.
Ϯʳ This warranty is subject to the exclusions and limitations described
below.
1. This warranty does not cover damages of products which are NOT
installed, operated, used and maintained in accordance with
written instructions.
2. This warranty does not cover damages resulted from isassemblies
or attempted disassemblies by parties other than KuDos® or its
authorized service representatives.
3. This warranty does not cover damages caused by improper
storage of the product, use of components not manufactured or
authorized by KuDos®, acts of God, accidents, use in a manner for
which they are not intended or use which is contrary to instructions
for the product.
4. This warranty does not cover ordinary wear and tear, which cannot
be imputed to defects in material and workmanship.
Ϯʳ KuDos® 's liability in all cases is limited to, and shall not exceed,the
purchase price paid.
Ϯʳ All revisions in warranty policy and product informations will be
included in new versions of handbooks. Individual notification will
NOT be issued.
KuDos Industrial Inc. U.S.A. Page: 10

Maintenance
Ϯʳ Always keep the product clean. Any sands or impediments might
cause malfunctions or even damages to the product. Routine renewal
of hydraulic fluid is required.
Ϯʳ Do NOT keep the product in places with high temperature, high humi-
dity, or direct sunlight.
Ϯʳ Operation with dies in accordance with the specifications in this hand-
book is required.
Ϯʳ Inform KuDos® authorized distributors in case of any abnormalities
or malfunctions of the product. Receipt and warranty card are requir-
ed for warranty services.
ϡ
ϡϡ
ϡDo Not disassemble/repair or attempt to disassemble/repair
the product.
ϮSuggested working temperaturesΚ-10к~ 40к
Ϯʳ Hydraulic fluid temperatures over 65кmight cause damages to
components sealed inside the product. It might also damage the
product severely.
Ϯʳ The hydraulic fluid pressure should be adjusted only by KuDos®
service representatives.
Ϯʳ Do NOT operate the product without dies in place, or the C-head
might be deformed or broken, the piston might be damaged, opera-
tors might even be injured.
Ϯʳ To keep the product in best working conditions, do NOT slam it on the
ground.
Page: 9 KuDos Industrial Inc. U.S.A.

Operation Manual - II
1. Release the hydraulic fluid pressure
and retract the piston before placing
diesΚPull out the moving handle
and rotate it clockwisely, press down
the release lever by pushing down
the moving handle, release the moving
handle and the product is ready to
work when the piston returns to its
starting position.
2. To place the upper die, pull up the spring pin ( #40) and push the
die into the open of C-head along its groove.
3. To place the lower die, press down the arresting pin ( #74) and push
the die into the open of C-head along its groove.
KuDos Industrial Inc. U.S.A. Page: 6

Operation Manual - III
4. Place the working cable and terminal into the open of C-head. To
reach the best results, the cable and terminal must be positioned
at the CENTER of the open top to balance the compression. It
might damage the dies or even deform the C-head if the cable and
terminal are off-center.
5. Exercise the moving handle back and forth to push the piston and
lower die forwards.
6. The rapid motion of piston with low hydraulic pressure will convert
to a slow motion with high pressure after the upper and lower dies
are tightly pressed.
7. Operation completes when the hydraulic pressure reaches 700 bars
at which the relief valve releases the internal pressure. Repeat step 1
and remove the cable. Pull up the spring pin (#40) to remove the
upper die, and press down the arresting pin (#74) to remove the
lower die.
8. Clean the product and dies after use. Apply rust preventive oil to the
product and dies before putting them back to the carrying case.
Page: 7 KuDos Industrial Inc. U.S.A.

Trouble-Shooting
ϮCompression of lugs cannot be implemented.
A. Insufficient hydraulic fluid : Routine refill or renewal of hydraulic
fluid is required.
B. Internal leakage: Contact KuDos® service representatives.
ϡ
ϡϡ
ϡDo NOT attempt to disassemble or repair the product.
C. Operation instructions were not followed. The product or dies have
been alreaady damaged.
D. Applied cables or terminals are over-specification.
ϮMoving handle is stuck or is unable to rotate to release the pressure.
A. Clean the moving handle to remove impediments.
B. Contact KuDos® service representatives for stuck torsional spring.
ϡ
ϡϡ
ϡDo NOT attempt to disassemble or repair the product.
C. Pressure can be released by pressing down the release lever
manually.
ϮDies can not be set in place or can not be removed.
A. Deformed C-head or dies. Contact KuDos® service representatives.
ϡ
ϡϡ
ϡDo NOT attempt to disassemble or repair the product.
B. Clean the grooves on C-head to remove impediments.
C. Clean the die seats on C-head to remove impediments.
Ϯʳ The piston is stuck or is unable to retract after operation. The piston
might be deformed by uneven stress distribution when the product was
operated with off-center cables and terminal. Contact with KuDos®
service representatives.
ϡ
ϡϡ
ϡDo NOT attempt to disassemble or repair the product.
KuDos Industrial Inc. U.S.A. Page: 8