Partex PHCT400-Kit Manual

D
Safe Operation & Maintenance Instructions
Hydraulic Compression Tool
PHCT400-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: 590mm.
Weight: 6.5 kgs.
Max pressure: 700bar.
Oil Capacity: 147cc.
ISSUE 10/13 ORIGINAL
PAGE 3
Product Description.
Subassembly.
Cast head
Release valve
Moving handle.
Fixed handle
Oil reservoir inside
Die locking pins.
Threaded body
Main ram
Features:
180 degree head rotation.
Open fronted cast head for insertion and extraction of crimp joint.
Integral overload protection valve.
Two stage hydraulic system for fast ram extension.
Light weight body.
Dies can be supplied separately.

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

ISSUE: 10/13 ORIGINAL
PAGE 6
Open moving handle, twist clockwise and
close handles together, this will bring the
release mechanism in position to release
hydraulic pressure. When the ram returns
to the starting position the tool is ready to
be operated.
Operating instructions.
To place the upper top die into position, pull
top die retaining pin upwards and insert die into
grooved housing, push die until it is centralized.
Release retaining pin making sure that the die is
now held in a central position by the retaining pin.
To place bottom die into position, press the
die retaining pin button (this is located at the
side of the ram) and insert die into grooved
housing. Push die until it is again centralized,
release button making sure that the die is now
held in a central position by the retaining pin.
1)
2)
3)

ISSUE: 10/13 ORIGINAL
PAGE 7
Operating Instructions
1. Place the desired cable and terminal into the open head of the tool
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. 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.
3. Continue pumping until both dies are touching. Operation is
complete when the hydraulic pressure reaches 700bar, and the
relief valve releases the internal pressure.
4. Twist the pump handle clockwise and close handles to retract the
piston. Remove the crimped terminal or reposition if further
compressions are required.
5. 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 8
Die sets

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

Removing Air From System.
1. Position the tool upside-down in a vice with the pump handle
in the open position.
the filler cap. Any excess oil should be wiped from tool before use.
of the rubber reservoir so the oil is slightly over flowing and insert.
After all air bubbles have been released, lightly squeeze the top
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
t wist clockwise and close moving handle.
This will release oil back into
the reservoir together with any trapped air bubbles. .
6.
.
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 ).
a) Ram advances and retracts when handle is pumped.

PARTS LIST.
ISSUE: 10/13 ORIGINAL
PAGE 12
No. Q'ty No. Q'ty
1 1 45 2
2 1 46 1
3 1 47 1
4 1 48 1
5 1 49 3
6 1 50 1
7 1 51 1
8 2 52 4
9 2 53 1
10 2 54 1
11 1 55 1
12 1 56 1
13 1 57 1
14 2 58 1
15 2 59 1
16 1 60 1
17 3 61 1
18 1 62 1
19 1 63 1
20 1 64 1
21 65 2
22 66 2
23 67 1
24 1 68 1
25 69 1
26 70 1
27 2 71 1
28 1 72 1
29 1 73 1
30 1 74 1
31 2 75 1
32 1 76 1
33 1 77 1
34 1 78 1
35 1 79 1
36 1 80 1
37 1 81 1
38 1 82 1
39 1 83 1
40 1 84 1
41 1 85 1
42 1 86 1
43 1 87 1
44 1Top Die Retaining Pin
Spring Pin
Compression Spring
O-ring
Back-up Ring
Copper WasherCompression Spring
Locating Pin
Back-up Ring
O-ring
Guide Bolt
Spring Holder
Inverse Ring
Magnetic Pin
Filler Cap
Main Ram
Die Retaining Button
Spring Pin
Compression Pin
Screw
Crescent
Handle Pin
Piston
Handle Pin
Oil Reservoir
Insulation Cap
Extension Tube
Handle Grip
FRP Pipe
Spring Pin
Insulation Tube
Conical Pin
Torsional Spring
Release Pin
FRP Pipe
Handle Grip
Guide Bolt
Screw
Parts
Spring Pin
Screw
Guide Block
Oil Seal
Spring Washer
Cap
Spring Pin
Bushing
Hook Spring
O-ring
Funnel
C Head
Split Pin
Locating Ring
Push-in Fastener
Compression Spring
Valve Screw
Ball Seat
Valve Screw
Insulation Cover
Relief Valve Set
O-ring
O-ring
Solid Filter
Screw
Ball
Screw
Ball
Screw
Back up Ring
O-ring
Compression Ring
Ball
O-ring
Compression Ring
Valve Screw
Compression Spring
Ball
Compression Spring
Parts
Tool Body
Oil Seal
O-ring
Locating Screw
Release Lever

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