KUDOS UB-412 Manual

O RIGINAL S AFE O PERATION & M AINTENANCE I NSTRUCTIONS MUST BE FOLLOWED
KuDos Hydraulic Crimper Tools are carefully inspected for quality and
tested for safety. We meet ISO 9001:2015, ISO 14001:2015, IECQ QC
080001, OHSAS 18001:2007 & UVDB.
KUDOS INDUSTRIAL INC. LLC
Hydraulic Crimper Tools
UB-412
SAFE OPERATION & MAINTENANCE INSTRUCTIONS
ATTENTION!
ORIGINAL INSTRUCTIONS
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Safety Warnings
Carefully read ALL warnings before operating this tool:
2 KuDos Industrial Inc. LLC
Hydraulic Crimper Tools
DO NOT attempt to disassemble or repair this
product. Doing so will violate the terms of the
warranty.
This product is NOT an insulator. Use
protective equipment when working near
power lines.
WARNING:
DO NOT use this tool on glass, plastic, wood or
any other materials which could shatter. Do not
exceed equipment ratings.
Always wear safety goggles when operating
this product. Projectiles or hydraulic fluid
under pressure can cause serious injuries.
Read all instructions and warnings carefully.
Follow all safety precautions to avoid injury or
damage to property.
ATTENTION!!
Only crimp terminals and sleeves that fit the
tool specifications. DO NOT attempt to crimp
oversized fittings
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KuDos Industrial Inc. LLC 3
Table of Contents
Hydraulic Crimper Tools
Thank you for using KuDos® products. This manual must be read
carefully prior to operating this product. Special attention
should be paid to the section ‘Safety Instructions’.
Damages and injuries caused by improper use of this product
are NOT included in our warranty. We would like to remind you
to work safely and to keep this manual on hand.
Safety Warnings ......................................................... 2
Table of Contents ....................................................... 3
Safety Instructions ..................................................... 4
Product Description .................................................. 5
Operating Instructions .............................................. 6
Die Sets ...................................................................... 8
Compression Diagrams ............................................. 9
Hydraulic Fluid Maintenance .................................... 10
Maintenance .............................................................. 11
Troubleshooting ........................................................ 12
Limited Lifetime Warranty ........................................ 13
Parts Guide ................................................................. 14
Part List ...................................................................... 15
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4 KuDos Industrial Inc. LLC
Safety Instructions
Follow ALL instructions to ensure safety:
W ORK A REA S AFETY
1. Keep the area around the equipment
clean and free of obstructions
2. Bystanders should stay clear of the
work area to ensure safety
P ERSONAL S AFETY
1. Stay alert while using this hydraulic
equipment to prevent serious injury.
Do not use under the influence of
drugs, alcohol or medicine.
2. Do not wear loose hair or clothes
that may get caught while the
equipment is in operation.
3. To reduce the risk of injury,
wear nonconductive gloves and
nonskid safety-shoes. Always
wear protective eyewear.
4. Work safely. Maintain your balance
and do not reach while operating
hydraulic tools.
T OOL U SE AND C ARE
1. Do not use this tool if there are
any abnormalities or damage to
any of its components.
2. Keep out of the reach of children.
All users should be familiar with
its use before operating.
3. Inspect the tool before and after
every use. Do not use this tool if it
is damaged in any way.
4. Personal injury can be caused by
operating damaged or poorly
maintained tools. Check for loose
parts before use.
5. Use only Kudos recommended
accessories with this tool.
6. Do not use this tool in wet conditions.
Store this tool in a dry place.
S ERVICE
1. This tool must be repaired by
qualified technicians. Do not
attempt to disassemble or repair
this tool yourself.
2. When having the tool serviced,
always use identical Kudos
replacement parts.
Hydraulic Crimper Tools
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Product Description
S PECIFICATIONS :
Hydraulic Crimper Tools
KuDos Industrial Inc. LLC 5
C APACITY :
F EATURES :
• Dimensions: 590 × 150 × 70mm
•Weight:6.5kgs
• Oil required: 147cc(cm3)
• Max. pressure: 700 bar(10,000psi)
• Max. output: 11.6 tons (114 kN)
• C-head opening: 40mm
• Max. compression: 32mm copper lugs
• Accepts all dies used by Alcoa, Burndy, T&B, Klauke,
Cembre and Blackburn 12-ton compressors
• Die sizes available: CU 16/25/35/50/70/95/120/150/185/
240/300/400
• 180° rotating tool head
• Adjustable pressure relief valve for overload protection
• Two-stage system with automatic low/high-pressure
conversion for rapid/slow advance
• Durable, lightweight fiberglass handles
• Accessories: KuDos plastic tool case
•Diesetsnotincluded
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6 KuDos Industrial Inc. LLC
Hydraulic Crimper Tools
Operating Instructions
BEFORE USE, DON’T FORGET TO…..
• Make sure all parts of the product are clean and rustless, and that
no loose parts exist.
• Check that no leakage occurs while the tool is resting or while the
product is tested without cables.
1. To start, rotate the moving handle clockwise
and bring the tool handles together.This
willdepress the release valve stem to fully retract
the piston.
2. Place the upper die by pulling up the spring pin
and pushing the die into the opening of the die
seat along the groove.
3. To place the lower die, push down the die
release button on the piston and slide the die onto
the die seat along its groove.
4. Position the cable and fitting into the C-head
opening. Pump the moving handle back and forth
to advance the piston.
5. Press the cable and fitting into the center of the
upper die as the piston advances. Off-centered
crimping may damage or deform the tool head.
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Hydraulic Crimper Tools
KuDos Industrial Inc. LLC 7
A FTER USE , DON ’ T FORGET TO ...
• Clean the product and check to ensure that all pieces are in
working condition.
• Apply rust preventive oil to the product and blades before
returning it to the carrying case.
6. The rapid motion of the piston with low hydraulic pressure will
convert to a slow motion with high pressure once the upper
and lower dies press together.
7. The operation will be complete when the hydraulic pressure
reaches 700 bar and the relief valve activates. There is an
audible click as the pressure is relieved.
8. Turn the moving handle clockwise and press the handles
together to return the piston to start position.
9. Follow connector specifications to apply the right number of
crimps. See the diagrams on page 9 for the crimping sequence.
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**IMPORTANT**
**Under any operation, the piston MUST BE FULLY RETRACTED
to keep the tool in good condition.
**Do not test the crimper without dies to avoid damage C-Head

8 KuDos Industrial Inc. LLC
Hydraulic Crimper Tools
1) Hex Dies For Copper Lugs
Die Sets
2) Hex Dies for Solderless Terminals
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KuDos Industrial Inc. LLC 9
Hydraulic Crimper Tools
Compression Diagrams
1)SLEEVE FITTINGS
Direction of Compression:
Single-sided/Outward
2)TERMINAL FITTINGS
Direction of Compression:
Outward
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ATTENTION:
•Use only new SHELL T15/T32 hydraulic fluid or
equivalent.
•The hydraulic fluid must be changed every 24 months.
•Using the incorrect type of oil will damage the seals in
the pump and cause the pump to malfunction.
Hydraulic Fluid Maintenance
Hydraulic Crimper Tools
1)REMOVING AIR FROM SYSTEM:
1.Position the tool upside-down in a vice with the pump handle in the open
position.
2.Unscrew the main handle from the body,then remove the reservoir bung/
cap.
3.Pump the moving handle a few times to advance the ram.
4.Press the release lever to release the pressure in the hydraulic circuit until
the ram is fully retracted and the oil has returned completely into the
reservoir.
5.Repeat the process several times to assure that all air bubbles are ejected.
6.Close the rubber reservoir and insert the filler cap,then reassenble the
Restore piston action by following the steps below:
2)REFILLING THE OIL RESERVOIR:
1.Check the oil reservoir every six months and make sure the reservoir
is full.
2. To refill the oil reservoir, follow the steps above to
disassemble the tool.
3.Do not use restored, used oil, or mix different kinds of oil.
10 KuDos Industrial Inc. LLC
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KuDos Industrial Inc. LLC 11
Hydraulic Crimper Tools
ATTENTION:
•Use only new SHELL T15/T32 hydraulic fluid or
equivalent.
•The hydraulic fluid must be changed every 24 months.
•Using the incorrect type of oil will damage the seals in
the pump and cause the pump to malfunction.
Maintenance
Follow these tips to ensure long product life:
• Hydraulic fluid must be replaced every 24 months.
• Keep the tool head free of dirt and metal chips. Use a lubricant to clean the tool
when necessary.
• Routine application of rust preventive oil to the product is needed. Avoid bringing
the tool into contact with water or solvents.
• DO NOT let the tool drop to the ground or into the carry-ing case to avoid damage to
internal parts or to the plastic case.
• DO NOT keep this product in places with high temperatures, high humidity, or direct
sunlight.
• Suggested working temperatures are -10°C to 40°C. Checkhydraulic fluid
specifications.
• Hydraulic fluid temperatures over 65°C might soften seals and cause fluid leaks.
• DO NOT DISASSEMBLE OR ATTEMPT TO REPAIR THIS TOOL.
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Troubleshooting
The fitting can not
be crimped:
Handle is stuck or
can’t release the
pressure:
Piston action is slow
or spongy:
Hydraulic Crimper Tools
12 KuDos Industrial Inc. LLC
• 1. One or more tool parts require repair. Replace the
parts immediately to prevent serious personal injury or
property damage.
• 2. Applied fitting is over-specification.
• 3. Insufficient hydraulic fluid. Follow steps on page 10 to add
fluid.
• 4. The cylinder piston might be deformed after crimping
an off-center fitting, or from the tool being used in a
manner for which it was not intended.
• 1. Clean the moving handle to remove impedi
ments.
• 2. Pressure can be released by pressing down the
release lever manually.
• 3. Torsional spring is stuck: Contact your KuDos®
service representatives.
•1. There is air in the hydraulic system. Follow steps on page
10 to expel any air in the system.
•2. Insufficient hydraulic fluid. Follow steps on page 10 to
add fluid.
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Limited Lifetime Warranty
• Kudos® hydraulic products are warranted against defects in materials and
workmanship for the life of the product. This is defined as that point in time
when the product no longer functions due to normal wear.
• This warranty is subject to the following exclusions and limitations:
1. This warranty does not cover damages to products which
are not installed, operated, used and maintained in
accordance with written instructions.
2. This warranty does not cover products that have been
worn out, damaged by improper storage, damaged or otherwise
altered, or from disassembly or attempted disassembly by parties
other than KuDos® or its authorized service representatives.
3. This warranty does not cover damages caused by the use
of components not manufactured or authorized by
KuDos®, acts of God, accidents, or use in a manner for
which they are not intended.
• KuDos's liability in all cases is limited to, and shall not exceed, the
purchase price paid. Kudos shall not be liable to any buyer for consequential
or incidental damages of any kind.
• Batteries, chargers, electric motors, gas engines and cutting blades
sold with Kudos products are not covered by this warranty. All electric
motors and gas engines are separately warranted by the manufacturer.
• Receipt and warranty card are required for warranty services.
• If the tool is found to be defective, in our sole judgement, Kudos will
either repair or replace the defective product or part.
• All revisions in warranty policy and product information will be
included in future versions of our manuals. Copies of this warranty
are available from the factory upon request.
Hydraulic Crimper Tools
KuDos Industrial Inc. LLC 13
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14 KuDos Industrial Inc. LLC
Hydraulic Crimper Tools
Parts Guide
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Hydraulic Crimper Tools
KuDos Industrial Inc. LLC 15
Part List
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I TEM : H YDRAULIC C RIMPER T OOL
M ODEL NO .: UB-412
S
ERIAL NO . :
I NSPECTION DATE :
Q.C. SUPERVISOR :
We hereby certify that the following KuDos product was
manufactured in accordance with our specifications and
has passed our quality inspection.
For KuDos Authorized
Distributor Use Only:
//
Date of Purchase (dd/mm/yy)
For Industry or Individual
Buyer Use Only:
//
Date of Purchase (dd/mm/yy)
Manufacture & Quality Certificate
KuDos Industrail lnc.LLC 15E North St. Dover, DE 10091, USA
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KuDos Mechanical
Manufacture & Quality Certificate
Item: Hydraulic Compression Tool
Model No: UC-6N
Serial No.
C Head No.
Date of Inspection:
Q.C. Supervisor:
授權經銷商 客戶資料
For KuDos Authorized For Industry or Individual
Distributor Use Only: Buyer Use Only
/ / / /
Date of Purchase (dd/mm/yy) Date of Purchase (dd/mm/yy)
We hereby certify that the following KuDos® product was
manufactured in accordance with our specifications and has
passed our quality inspection.
KuDos Mechanical Co., Ltd
No.151, Sec. 1, Pei Shen Rd., Shen-Keng District, New Taipei City, Taiwan
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KuDos Mechanical
KuDos Mechanical Co., Ltd
Safe Operation & Maintenance Instructions
Hydraulic Compression Tool
Hydraulic Compression Tools are carefully inspected for quality
and tested for safety. We follow ISO 9001: 2015/ ISO 14001: 2015/ IECQ QC
080001/ OHSAS 18001: 2007 & UVDB
ATTENTION!
Safe Operation & Maintenance Instructions must be followed.
UC-6N
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KuDos Mechanical
Table of Contents
Table of Contents…………………………………………………….1
Safety Instructions…………………………………………………2
Product Description…………………………….…………………...3
Maintenance’…………………………………………………………4
Operating Instructions…………………………….…………………5
Compression Diagrams…..…………………………………………6
Trouble–Shooting……………………………..……………………7
Limited Lifetime Warranty…………………………………………8
Diagram of Components………………………….……………….9
Table of Components………………………….……………….10
Manufacture & Quality Certificate
1
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KuDos Mechanical
Table of Components UC-6N
No. Part Q’ty No. Part Q’ty
1 Cylinder 1 43 Guide piece 1
2 Relief valve 1 44 Pivot roller 2
3 O-Ring 2 45 Locating pin 2
4 Locating screw 1 46 Indent die 1
5 Release valve stem 1 47 Indent die 1
6 O-Ring 1 48 Spring pin 1
7 Compression spring 1 49 Compression spring 2
8 Pump piston 1 50 Indent ide 2
9 Dust seal 1 51 Bearing retainer 2
10 O-Ring 1 52 Pin 10
11 Back up ring 1 53 Bushing 1
12 Ball 1 54 Spring pin 2
13 Screw 1 55 Screw 2
14 Screw 1 56 Cylinder cover 1
15 Valve screw 1 57 Cylinder cover 1
16 Back up ring 1 58 Screw 2
17 O-Ring 1 59 Screw 3
18 Compression spring 1 60 Cap 1
19 Ball 3 61 Bushing 4
20 Ball seat 1 62 Spring pin 1
21 Compression spring 2 63 Hinge pin 1
22 Copper washer 1 64 Arresting pin 1
23 Valve screw 1 65 Crescent 2
24 Valve screw 1 66 Torsional spring 1
25 Oil screen 1 67 Guide bolt 1
26 Oil screen 1 68 Release pin 1
27 Push in fastener 1 69 Fiber glass pipe 1
28 O-Ring 1 70 Spring pin 1
29 Ball 1 71 Handle grip 1
30 Compression spring 1 72 Insulation cap 1
31 Ball 2 73 Extension tube 1
32 Compression spring 2 74 Spring pin 1
33 Push in fastener 2 75 O-Ring 1
34 Ram spring 1 76 Oil reservoir 1
35 Ram 1 77 Magnetic bar 1
36 Back up ring 1 78 Filler cap 1
37 O-Ring 1 79 Insulation cap 1
38 Screw 1 80 Fiber glass pipe 1
39 Back up ring 1 81 Handle grip 1
40 O-Ring 1
41 Insulation cap 1
42 Hook spring 1
10
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