Partex PHCT240-Kit Manual

D
Safe Operation & Maintenance Instructions
Hydraulic Compression Tool
PHCT240-Kit
ATTENTION
Safe Operation & Maintenance Instructions must be followed.
PARTEX MARKING SYSTEMS (UK) LTD
61-64 Station Road, Coleshill,
Birmingham B46 1JT
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.partex.co.uk
ISSUE: 10/13 ORIGINAL

Table of Contents
Table of Contents ……………………………………………….1
Safety Instructions ………..…………………………………… 2
Product Description …………..…………….………………….. 3
Maintenance ………………….………………………………… 4
Operating Instructions …..……….………….………….…5, 6, 7
Dies ……...………………………….………….…………………8
Compression Diagram …………….………….…………………9
Trouble–Shooting …………….……………..……………10, 11
List of Components …………………………………………….12
Diagram of Components ………………...……………………13
ISSUE: 10/13 ORIGINAL
PAGE 1.

This manual must be read carefully prior to operating this product.
Special attention should be
made
to the section “Safety Instructions”.
Damages
and
injuries
caused
by
improper
use
of
this
product
are
NOT
covered
in
our
warranty.
Safety Instructions
■ Follow ALL instructions to ensure safety .
WARNING
Keep hands away from the compression area
while operating this product.
This product is fully insulated.
Proper equipment should be used to avoid
electrical shock.
ATTENTION
To prevent personal injury always wear goggles
when operating this product.
Read all instructions, warnings, and cautions
carefully. Follow all safety precautions to avoid
personal injury or property damage.
ISSUE: 10/13 ORIGINAL
PAGE 2

Length: 375mm.
Weight: 2.8kgs.
Max pressure: 550bar.
Oil Capacity: 56cc.
ISSUE 10/13 ORIGINAL
PAGE 3
Rubber Handle
Grips.
Product Description.
Subassembly.
Features:
Latch type head for easy die changes and removal of connectors
Built-in pressure relief valve for constant compression
Adjustable ram stroke, 10-15 mm.
Spring loaded pump handle allows one-handed operation.
Small handle spread of 210mm.
Dies can be purchased separately.
Release Lever.
Moving Handle
Head.
Top Die Holder Latch.
Oil Reservoir
inside
Fixed Handle.
Head Latch.
Bottom Die
Holder.

Maintenance
■ Tool should be kept free from dust, dirt and foreign particles
were possible.
■ Routine application of rust preventive oil / grease to the product is
periodically required and should be applied liberally to the
surface of the tool.
■ Avoid bringing the tool into contact with water or solvents.
■ Do NOT store this product in places with high temperatures, high
humidity, or direct sunlight. Hydraulic fluid temperatures over
65ºC might cause damage to components sealed inside the unit.
■ working temperatures：-10°C ~ 40°C.
■ Before storage ensure that the ram and piston are fully retracted
within unit.
■ DO NOT ATTEMPT TO REPAIR THIS TOOL
Inform Partex or
their authori
z
ed distributors.
ISSUE: 10/13 ORIGINAL
PAGE 4

Operating Instructions
Before operation:
1. Make sure all parts of the product are clean and free from debris , check for any
loose parts.
2. Check that no leakages are evident while the tool is in resting position or while the
tool is tested without terminal connector.
ATTENTION Do not operate crimp tool when dies are not in place.
ATTENTION Be sure to select correct dies to suit the connector you are crimping.
Improper selection can result in danger to the operator, damage to the unit or an
inferior joint.
During operation:
1. Keep tool clean and free from debris. Excessive dirt & debris can contribute to the
breakdown of the hydraulic system. Regular checks during operation cycle should be
made for foreign matter or debris and removed immediately.
3. Stop operating immediately if abnormalities occur and refer to the
Trouble-Shooting section of this manual, if:
• Compression of lugs cannot be completed
• Dies cannot be inserted or removed
• Piston is stuck or unable to retract after operation
After operation:
1. Clean the product and check that all pieces are in fine working condition.
2. Apply rust preventive oil to the product and dies before returning it to the
carrying case.
ISSUE 10/13 ORIGINAL
PAGE 5

Operating Instructions
1. Open moving handle, press the release trigger
and close handle, this will release the hydraulic
pressure in the tool. When the ram and bottom die
holder return to the starting position the tool is ready
to be operated.
2. Pull back the latch to open the head, the
yoke will now spring open.
3. Slide the dies into the top and bottom
die holders. making sure the dies are
matching and seated correctly. The head
can then be closed.
ISSUE: 10/13 ORIGINAL
PAGE 6

Operating Instructions
1. Place the desired cable and terminal into the open head of the tool
and snap the head back into the closed position.
NOTE: For best results, the cable and terminal must be
positioned at the CENTER of the upper die as this will
balance the compression load ratio and not cause distortion of
die or head.
2. Release the handle catch between the bottom of the handles, the
moving handle will then spring open.
3. Pump the moving handle, the ram will rapidly advance. When the
lower die makes contact with the terminal connector the tool will
then slowly press the terminal until full compression is reached.
4. Continue pumping until both dies are touching. Operation is
complete when the hydraulic pressure reaches 550bar, and the
relief valve releases the internal pressure.
5. Press the release trigger and close handles to retract the piston.
Open the tool head and remove the crimped terminal or reposition
if further compressions are required.
6. Clean the product and dies after use. Apply rust preventive oil to
the product and dies before putting them back in the carrying
case.
ISSUE: 10/13 ORIGINAL
PAGE 7

Dies
Die No. Side A B C
10 to 16 A CU10 5.45 2.3 12
B CU16 6.8 2.85 12
25 to 35 A CU25 8.35 3.5 9
B CU35 9.4 4 9
50 to 70 A CU50 11.35 4.8 9
B CU70 13.8 6.05 9
95 to 120 A CU95 16.17 6.9 9
B CU120 18.05 7.6 9
150 A CU150 20.15 8.55 6
185 A CU185 22.15 9.35 6
240 A CU240 25.6 11.1 6
ISSUE: 10/13 ORIGINAL
PAGE 8

Compression Diagrams
■ Butt connectors.
Direction of Compression: Single compression headed die.
■ Terminal Connectors.
Direction of Compression: Single Compression headed dies.
ISSUE: 10/13 ORIGINAL
PAGE 9.

Trouble-Shooting
Compression cycle cannot be completed:
A. Incorrect combination of die sets and compression terminals
B. Damaged die sets
Dies cannot be inserted or removed:
A. Deformed tool head runner or die holder.
B. Head die runners dirty or not lubricated .
Piston unable to advance or retract during operation:
A. Piston damaged or distored.
B. Die runners damaged.
Do NOT attempt to repair this unit. Return to supplier.
C. Pressure leakage or oil leakage externally or internally
C. Pressure leakage or oil leakage.
ISSUE: 10/13 ORIGINAL.
PAGE 10

a) Ram advances
and retracts when handle is pumped ..
Removing Air From System.
1. Position the tool upside-down in a vice with the pump handle in
the open position.
2. Unscrew the fixed main handle from the body, then remove the
reservoir
end cap.
3. Pump the moving handle and press the release button in at the
same time, this will open hydraulic oil chambers and will allow the
air bubbles to rise out of the tool system into the oil reservoir. The
moving handle should be pumped for a minimum of 10 operations.
4. It is advised to leave tool upside down with end cap off for a further
10 to 15 minutes, this will allow any air bubbles that are trapped in
reservoir to rise and escape.
5. Top up hydraulic fluid if required , pump the moving handle
so the ram advances but does not come under pressure. Now
press release trigger and close moving handle.
This will
release oil back into the reservoir together with any trapped air bubbles.
6. After all air bubbles have been released, lightly squeeze the top
of the rubber reservoir so the oil is slightly over flowing and insert
the filler cap.
Any excess oil should be wiped from tool before use.
Oil
Refilling:
■ Check oil level periodically and top up if required.
■
OIL TYPE
:
TELLUS GRADE 15
ONLY
.
ISSUE: 10/13 ORIGINAL
PAGE 11
b) Ram does not move when handle is pumped.
c) Unit does not reach pressure.
Air in hydraulic system
( repeat this process several times to ensure that all air bubbles have been removed ).

No. Parts Q'ty No. Parts Q'ty
1 CYLINDER 1 35 RELEASE KEY 1
2 COMPRESSION SPRING 1 36 HOOK SPRING 1
3 RELEASE VALVE STEM 1 37 TORSIONAL SPRING 1
4 BONDED SEAL 1 38 TRIGGER 1
5 SCREW 1 39 OIL RESERVOIR 1
6 O-RING 1 40 FILLER CAP 1
7 BACK-UP RING 1 41 MAGNETIC BAR 1
8 BALL 5 42 PIN 1
9 BALL 4 43 O-RING 1
10 COMPRESSION SPRING 1 44 HANDLE GRIP 1
11 SPRING SEAT 1 45 PUMP PISTON 1
12 DUST SEAL 1 46 SPRING PIN 1
13 BONDED SEAL 1 47 HOLDING BAND 1
14 COMPRESSION SPRING 3 48 PIN 1
15 COMPRESSION SPRING 2 49 DUST SEAL 1
16 COMPRESSION SPRING 1 50 COMPRESSION SPRING 1
17 PUSH IN FASTENER 5 51 SCREW 1
18 OIL SCREEN 2 52 MAIN PISTON 1
19 SCREW 1 53 TORSIONAL SPRING 2
20 SCREW 3
54,55,57
LATCH 1
21~25 RELIEF VALVE SET 1 YOKE 1
26 FIBER GLASS PIPE 1 PIN 1
27 HANDLE GRIP 1 56 DIE SIZING LOCK PIN 1
28 EXTENSION TUBE 1 58 DIE HOLDER 1
29 HINGE PIN 3 59 HINGE PIN 2
30 DUST SEAL 1 60 CYLINDER COVER 1
31 PUMP HANDLE 1 61 SCREW 1
32 O-RING 1 62 CRESCENT 4
33 BACK-UP RING 1 63 BALL PLUNGER 4
34 CRESCENT 6 64 COMPRESSION SPRING 1
PARTS LIST.
ISSUE: 10/13 ORIGINAL
PAGE 12

Parts Drawing.
ISSUE: 10/13 ORIGINAL
PAGE 13.