KUDOS HYCP-4413 Manual

S
AFE
O
PERATION
& M
AINTENANCE
I
NSTRUCTIONS
KuDos Mechanical Co., Ltd
Hydraulic Crimper Tool
HYCP-4413
ATTENTION!
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.

Hydraulic
Crim
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Tools
2 KuDos Mechanical
WARNING:
DO NOT attempt to disassemble
or
repair this product. Doing so will
violate
the
terms
of
the
warranty.
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.
This product is NOT an insulator. Use
protective equipment when working
near power lines.
ATTENTION!
Read all instructions and warnings
carefully. Follow all safety precautions
to
avoid injury or damage to property.
Only crimp terminals and sleeves that
fit the tool specifications. DO NOT
attempt to crimp oversized fittings
Safety Warnings
Carefully read ALL warnings before operating this tool:

Hydraulic
Crimp
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Tools
3 KuDos Mechanical
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.
Table of Contents
Safety Warnings ........................................ 2
Table of Contents ...................................... 3
Safety Instructions ................................... 4
Product Description .................................. 5
Operation Instructions ............................... 6
Die Sets ................................................ 8
Compression Diagrams .............................
9
Hydraulic Fluid Maintenance ........................ 10
Maintenance ............................................ 11
Troubleshooting ...................................... 12
Limited Lifetime Warranty ........................... 13
Parts Guide ............................................. 14

Hydraulic
Crim
ping
Tools
4 KuDos Mechanical
Safety Instructions
W
ORK
A
REA
S
AFETY
1.
Keep the area around the equip-
ment clean and free of obstruc-
tions
2.
Bystanders should stay clear of
the work area to ensure safety
P
ERSONAL
S
AFETY
1.
Stay alert while using this hydrau-
lic equipment to prevent serious
injury. Do not use under the influ-
ence of drugs, alcohol or medi-
cine.
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 non-
skid safety-shoes. Always wear
protective eyewear.
4.
Work safely. Maintain your bal-
ance and do not reach while oper-
ating 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 condi-
tions. 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.

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Crimp
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Tools
5 KuDos Mechanical
Rotating C
-
head
Moving handle
Relief
valve
Product Description
S
PECIFICATIONS
:
FEATURES:
C
RIMPING RANGE
:
•
Dimensions: (L)641 × ( W)150 × (H)70mm
•
Weight: 7.6kg
•
Max. pressure: 700 bar/10,000psi
•
Max. output: 12.7 tons/125KN
• Jaw opening: 44mm
•
Oil required: 80cc
•
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
•
Die sets sold separately
•
Max. compression: 40mm 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
Die-release
button
Main piston
and spring
Fixed handle
Oil reservoir bung

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Crim
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Tools
6 KuDos Mechanical
B
EFORE 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.
Operating Instructions
1.
To start, rotate the moving handle clockwise
and bring the tool handles together. This will
depress 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.

Hydraulic
Crimp
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Tools
7 KuDos Mechanical
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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Crim
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Tools
8 KuDos Mechanical
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
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
Die Sets
1) H
EX DIES FOR
C
OPPER
L
UGS
2) H
EX DIES FOR SOLDERLESS TERMINALS

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9 KuDos Mechanical
Compression Diagrams
1) S
LEEVE
F
ITTINGS
Direction of Compression:
Single-sided/Outward
2) T
ERMINAL
F
ITTINGS
Direction of Compression:
Outward

Hydraulic
Crim
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Tools
10 KuDos Mechanical
ATTENTION:
•
Use only new SHELL T15 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
Restore piston action by following the steps below:
1) R
EMOVING AIR FROM THE 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
reassemble the main handle.
2) R
EF ILLING THE OI L R ESER V O IR
:
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 dis-
assemble the tool.
3.
Do not use restored, used oil, or mix different kinds of
oil.

Hydraulic
Crimp
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Tools
11 KuDos Mechanical
ATTENTION:
•
KuDos
tools
must
be
serviced
by
a
qualified
technician.
•
Replace any worn or damaged parts immediately. Only
use
parts supplied by Kudos.
• Contact KuDos service representatives to request parts or
for
problems
not
shown
here.
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 tempera-
tures, high humidity, or direct sunlight.
• Suggested working temperatures are -10°C to 40°C. Check
hydraulic fluid specifications.
•
Hydraulic fluid temperatures over 65°C might soften seals
and cause fluid leaks.
•
DO NOT DISASSEMBLE OR ATTEMPT TO REPAIR THIS TOOL.

Hydraulic
Crim
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Tools
12 KuDos Mechanical
Troubleshooting
The fitting cannot
be crimped:
Handle is stuck or
can’t release the
pressure:
Piston action is slow
or spongy:
•
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.

Hydraulic
Crim
ping
Tools
14 KuDos Mechanical
Parts Guide

Hydraulic
Crimp
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Tools
15 KuDos Mechanical
No.
Part
Q’ty
No.
Part
Q’ty
1 Set Screw 1 43 Backup Ring 1
2 Spring 2
44
O
-
Ring
1
3 Die Holder Pin 1 45 Backup Ring 1
4
Spring Pin
1 46 Pump Piston 1
5
Die Release Button
1 47 Spring 1
6
Guide
Plate
1 48 O-Ring 1
7
Screw
1 49 Release Pin 1
8
Washer
2
50
Locating Screw
1
9
Screw
2 51 O-Ring 1
10
C
-
Head
1 59 Steel Ball 1
11
Piston
1 60 Set Screw 1
12
Die Release Button
1
61 Cylinder Cover 1
13
Die Holder Pin
1 62 Gasket 1
14
Spring Pin
2 63 O-Ring 1
15
Oil Seal
1 64 Oil Reservoir 1
16
Backup Ring
1 65 O-Ring 1
17
O
-
Ring
1 66 Magnetic Bar 1
18 Spring Rod 1 67 Oil Reservoir Cap 1
19 Spring 1 68 Stop Collar 1
20 Spring 1 69 Spring Pin 1
21 Spring Seat 1 70 Body Handle 1
22 Circlip 1 71 Insulation Tube 1
23 Hydraulic Cylinder 1 72 Tool Handle Grip 1
24 Set Screw 2
73
Handle Insulator Cover
1
25 Spring 2 74 Circlip 2
26
Steel Ball
2
75
Bushing
4
27 Spring 1 76 Spring Pin 1
28
Steel Ball
1
77 Hinge Pin 1
29 Spring Pin 1
78
Arresting Pin
1
30 Steel Ball 3 79 Conical Pin 1
31 Spring 1 80 Handle Insulator 1
32 O-Ring 1 81 Torsion Spring 1
33 Backup Ring 1 82 Guide Bolt 1
34 Valve Screw 1 83 Release Pin 1
35
Spring
1
84 Spring Pin 1
36 Screw 1
85
Moving Handle Tube
1
37 Screw 1 86 Tool Handle Grip 1
38 Set Screw 1 87 Steel Ball Seat 1
39 Oil Filter 1 88 Spring 1
40
Strainer
1
89
Copper Washer
1
41 Push-in Fastener 1
90
Relief Valve Set
1
42 O-Ring 1