Power Team C12-HTR series Use and care manual

C12-HTR / 12-HTR REMOTE HYDRAULIC
CRIMPING TOOL
Form No. 1000023A
C12-HTR-C SERIES
12-HTR SERIES
Operating Instructions and
Parts List for:
INTRODUCTION
The 12-HTR compression head was designed for installing
tubular compression connectors on electrical conductors.
The 12-HTR remote compressor is a light weight, remote
powered, hydraulic tool that can be operated in any position.
The single acting cylinder develops twelve tons of thrust at
10,000 psi (68.9 MPa). Any pump capable of this pressure,
with a safety valve setting between 9,600 psi (66.2 MPa) and
10,400 psi (71.7 MPa) may be used.
The 0.92 inch (23.4 mm) open C-head permits the
compressor to be hooked over the conductor or accessory,
and the die locking devices allow it to be moved along without
accidentally dislodging the die halves.
THE 12 HTR AND C12-HTR TOOL IS NOT TO BE USED
FOR "HOT LINE" WORK.
SPECIFICATIONS
TOOL SECTION:
1.81 (4.60 CM) DIA.RAM, .96 (2.44 CM) STROKE WITH DIES.
CRIMPING FORCE, 13.1 U.S. TONS AT10,000 PSI (11.9 METRIC TONS
AT 70,000 kPA (700 BAR)
OIL TYPE USED, AMOCO RYKON MV.
OVERALL DIMENSIONS:
2.75 x 4.87 x 10.25 INCHES LONG (6.98 x 12.37 x 26.03 CM LONG)
TOTAL WEIGHT, 10.3 LBS. WITH OIL (4.7 kg WITH OIL)
CRIMPING CAPACITY:
NO.8 THRU 500 MCM CU GROUNDING TERMINALS AND SPLICES
NO.8 THRU 250 MCM CU GROUNDING TAPS AND 3/4 INCH GROUND ROD
NO.8 THRU 750 MCM CU INSULATED AND UNINSULATED TERMINALS
NO.8 THRU 750 MCM CU ALUMINUM TERMINALS
NO.8 THRU 350 MCM CU ALUMINUM SPLICES
NO.6 THRU 556.5 26/7 ACSR STRANDING
COUPLERS:
MALE COUPLER ASSEMBLY (Power Team Part No. 25599)
WARNING
Sheet No. 1 of 5
Rev 1 Date: 13 June 2005
© 2005 SPX Corporation
Tech. Services: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
SPX Corporation
5885 11th Street
Rockford, IL 61109-3699 USA
Internet Address:
http://www.powerteam.com
®

Operating Instructions and Parts List, Form No. 1000023A, Back sheet 1 of 5
IMPORTANT SAFETY INFORMATION
This is the safety alert symbol.
It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death
Denotes an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
Denotes a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Denotes a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
Caution used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage.
Denotes an operating or service procedure or condition
considered essential for expedient and efficient
operation and service.
It is the operators responsibility to read and
understand the following safety statements,
• Only qualified operators should install, operate,
adjust, maintain, clean, repair, or transport this
machinery.
• Inspect tool before use. Replace any worn or
damaged parts. Failure to observe these warnings
can result in severe injury or death.
Keep hands away from the crimping tool head
when crimping.
IMPORTANT
To help prevent personal injury,
• Always wear eye protection whenever
operating hydraulic equipment.
• Always wear hearing protection as
required.
• Operation, repair, or maintenance of hydraulic
equipment should be performed by a qualified
person who understands the proper function of
hydraulic equipment per local directives and
standards.
• Hydraulic equipment must be assembled correctly
and then checked for proper function before use. Use
hydraulic components of the same hydraulic
pressure ratings. An appropriate hydraulic pressure
gauge is recommended to monitor pressure.
• Never place your hands or other body
parts near a hydraulic fluid leak.
• Never use your hands or other body parts
to check for a possible leak.
High pressure fluid can be injected under your skin
causing serious injury and/or infection.
• Exercise caution to avoid the risk of fire.
An incomplete crimp can cause a fire. Use
proper die, connector and cable. Improper
combinations can result in an incomplete
crimp.
• DO NOT USE FOR HOT LINE WORK
• This tool is not insulated. When using this
unit near energized electrical lines, use
proper personal protective equipment.
• This tool is intended for two-handed operation.
Maintain a firm grip on both handles during
operation. Using this tool in any other manner can
result in injury or equipment damage.
• Do not advance Ram without Dies inserted.
• Properly dispose of all fluids, components, and
assemblies at the end of their useful life.
• Hydraulic fluid should be compatible with all
hydraulic components.
IMPORTANT
CAUTION
CAUTION
CAUTION
WARNING
WARNING
WARNING
WARNING
DANGER

Operating Instructions and Parts List, Form No. 1000023A
OPERATING INSTRUCTIONS
DO NOT OPERATE THE COMPRESSOR WITHOUT DIES.
Select the proper dies for use on the accessory to be compressed. Push the die release button on the C-head and
slide one of the identical die-halves into position. The die retainer pin locks the die in place.
The connection of the compressor and the hydraulic hose is quickly and easily made by the use of a quick coupler,
the female half being part of the compressor and the male half located on one end of the hydraulic hose. With this
connection properly made, the ball check valves in both female and male halves of the quick coupler are open to
permit free oil flow.
Connect compressor and hose to any suitable hydraulic pump that has a pressure output of 10,000 psi. The mating
half of quick coupler supplied with compressor is Power Team No. 25599. Pump should be equipped with a 2 or 3-way
valve. Put the valve in the retract position and retract compressor piston fully.
Place the compressor in position over the accessory to be compressed. If the accessory is larger in diameter than the
throat opening of the C-head, put the compressor over the conductor and then slide it over the accessory in the
correct position for the first compression.
Place valve in advance pisition and advance piston with pump. When the dies touch on the frame side, compression
is complete.
Release the pressure at the pump and the lower die-half will retract. When compressing connectors, overlap each
bite of the dies just enough to make a smooth continuous compressed section.
Do not use the compressor for any purpose other than that for which it was designed.
This tool has been manufactured to precision tolerances. It should be used with the
same care and attention as any other fine piece of equipment.
REPLACING HYDRAULIC SEALS
Maintenance and repair of this tool should be provided with the same reasonable care given other fine equipment.
Service should be performed by adequately trained personnel in repair shops under clean conditions. For those
owners having adequately staffed repair facilities, a hydraulic seal replacement kit No. 4-1075 containing O-rings,
gaskets, etc., needed for one complete replacement of hydraulic seals in the compressor. Include compressor serial
number when ordering all parts.
To replace the seals it is necessary to separate the C-head and piston assemblies from the cylinder. Remove both
die halves. Removing the quick coupler drains the oil and aids in dis-assembly. Remove screw and washer to unlock
cylinder.
Unscrew the C-head and the piston will also rotate. After nine complete turns the piston spring rod is unthreaded
from within the cylinder and the piston guide arrangement should be removed. Further rotation will separate the C-
head from the cylinder. Pull the piston from the cylinder. All seals and rings are now accessible.
Reassemble with clean parts lubricated with the same grade of oil used in the remote pump.
The steel piston washer and leather wiper are installed on the outside of the piston with the steel washer next to the
shoulder on the piston.
Insert piston into cylinder, rotate assembly until hand tight. Backoff one-half turn to permit the piston wipers to center
themselves in the C-head bore. Thread the C-head onto the cylinder until the bottom of the die groove in piston is
flush at a corresponding point on the C-head. Continue rotation until the key slots align. At this attitude, top of piston
should not have entered C-head opening and a die-half can be inserted in piston groove.
Reassemble the piston guide arrangement with Loctite on screw threads.
WARNING
WARNING
Sheet No. 2 of 5
Rev 1 Date: 13 June 2005

Operating Instructions and Parts List, Form No. 1000023A, Back sheet 2 of 5
SERVICING INSTRUCTIONS
REPLACING HYDRAULIC SEALS (continued)
Invert the tool and fill the cylinder with oil. Bleed air from cylinder by rocking tool back and forth. Assemble 3/8 inch
female quick coupler.
It is important that the compressor be full of oil and free of air. The simplest way to fill and bleed the compressor is to
install a set of dies and invert the tool. Attach a pump placing it in position above the compressor. Advance and
retract the piston several times.
DO NOT USE BRAKE FLUID OF ANY KIND.
PREVENTIVE MAINTENANCE
The majority of service troubles are caused by dirt collecting about the tool or in the oil system. Keep the tool clean
and prevent foreign matter from entering the compressor while filling the remote pump reservoir.
Refer to the “Specifications” for the proper oil when replenishing or replacing the fluid.
Wiper clean both sections of the quick coupler before connection and replace dust caps after disconnection. Lubricate
all moving parts and keep the piston guide screw tight.
DO NOT OPERATE COMPRESSORS WITHOUT DIES.
4
3
5
6
2
1
1. Top Die Release Button
2. Die half
3. Piston
4. Lower Die Release Button
5. Female Coupler
6. C-Head
Illustration
WARNING
WARNING

Operating Instructions and Parts List, Form No. 1000023A
INSTRUCTIONS FOR CONVERSION TO C12-HHT
1. Fully retract tool ram and make sure all pressure has dissipated.Disconnect tool from hose to pump.
2. Place tool in a vise with handles pointing upward. Remove adhesive label covering slot in cylinder.
3. Pry hooked end of retaining wire out of slot in cylinder.
4. Holding hooked end of wire with pliers, rotate cylinder to force retaining wire out of groove and through slot.
Discard wire.
5. Carefully separate end cap assembly from cylinder assembly, holding discharge spring in place.
6. Apply lubricant to groove in pump block and to retaining wire.
7. Insert pump block assembly into back end of cylinder assembly. Rotate cylinder assembly until hole in pump
block appears in slot in cylinder.
8. Place hooked end of new wire from conversion kit into hole in pump block. Align free length of wire along slot
in cylinder. Rotate cylinder assembly in opposite direction to feed wire through slot and into groove.
9. When wire is fully engaged, hooked end will snap out of hole in pump block to permit full head rotation.
Seal slot with new adhesive label.
10. Purge air from tool using normal fill and bleed procedures.
Sheet No. 3 of 5
Rev 1 Date: 13 June 2005
®
SPX Corporation, Rockford, IL 61109 USA
http://www.powerteam.com Made in USA
®
SPX Corporation, Rockford, IL 61109 USA
http://www.powerteam.com Made in USA
®
SPX Corporation, Rockford, IL 61109 USA
http://www.powerteam.com Made in USA
WIRE SLOT IN CYLINDER
12-HTR TOOL
C HEAD SUB-ASSEMBLY
(PART NUMBER 3000084 coated
or 4-0644 uncoated)
PUMP MECHANISM SUB ASSEMBLY
(PART NUMBER 3000089)
CONVERSION ASSEMBLY
(PART NUMBER 4-0766)
1-RETAINING WIRE
1-WRAP AROUND DECAL

Operating Instructions and Parts List, Form No. 1000023A, Back sheet 3 of 5
TROUBLE SHOOTING
If the ram will not extend completely, it will generally be found that there is an insufficient amount of oil in the crimper's
hydraulic system.
If the dies will not close and pumping is difficult, check the die number to make certain the proper size die is being
used on the accessory. If the dies will not close and pumping becomes easier, usually additional oil is needed in the
hydraulic system.
If the ram will not retract completely, it will generally be found that there is too much oil in the hydraulic system. Drain
enough to permit complete retraction. If the ram will not retract and the oil reservoir is not full, the ram is likely being
held by a deformed washer.
A small amount of leakage is desirable around the ram to lubricate this parts. If enough leakage occurs to cause the
oil to run, the packing should be replaced.
If the dies do not lock in position, the action of the retaining pins is probably restricted by dirt. Clean and oil these
parts.
If it is difficult to unlock the die-halves, the die release buttons should be lubricated. The die retaining pin set screw in
the C-head above the die release button is staked in position. To further tighten this screw will make it difficult or
impossible to release the die.
COMPATIBLE HYDRAULIC FLUIDS:
The use of Amoco Rykon MV oil is recommended. Compatible fluids include:
Mobil DTE 13 Mobil ATF 220 Shell Tellus 32 Arco Dexron III Citgo AW32 Citgo Dexron III
Other fluids also may be used if they meet or exceed the following specifications:
Viscosity: 181 SSU at 100 degree F.
Flash Point: 350 degree F
Pour Point: -50 degree F:

Operating Instructions and Parts List Form No. 1000023A
PARTS LIST
Sheet No. 4 of 5
Rev 1 Date: 13 June 2005
11000055 1 Decal (Warning & Caution)
2420691 1 Decal (Product Blank)
33-9678 1 Wire, Retaining
41000053 1 Decal, (Tradename Power Team)
59797 1 Plug, Dust
69796 1 Coupler Female (3/8” NPTF)
73-9990 1 Cap, End
83000084 1 C-Head / Ram / Cylinder
Assembly (PVC-coated)
84-0644 1 C-Head / Ram / Cylinder
Assembly (Non PVC-coated)
ITEMS NOT SHOWN:
3-1294-OR9 1 Case, 12-HTR Orange Carrying
Item Part No. Item Part No.
No. No. Req’d Description No. No. Req’d Description
APPLY "WHITE LUBE" LITHIUM
(213083) GREASE TO WIRE AND
GROOVE BEFORE ASSEMBLING
B
B
SECTION B-B
A
A
SECTION A-A
3
4
2
5
6
8
7
1
C12-HTR / 12-HTR

Operating Instructions and Parts List, Form No. 1000023A, Back sheet 4 of 5
PARTS LIST
13-1237 1 Shaft
24-0647 1 C-Head (Non PVC coated)
35-0662 1 Screw, Set
43-1239 1 Spring, Compression
55-1265 1 Pin, Drive
63-1238 1 Pin, Retainer
Item Part No. Item Part No.
No. No. Req’d Description No. No. Req’d Description
AA
123456
SECTION A-A
1
2
3
4
5
6
7
14-1322 1 Tube, Transfer
25-3245 1 Ring, Back-Up
310266 1 O-Ring
43-9683 1 Retaining, Swivel
511032 1 Ring, Retaining
63-9681 1 Spring, Tension
73-9682 1 Retainer, Threaded
Item Part No. Item Part No.
No. No. Req’d Description No. No. Req’d Description
C-HEAD ASSEMBLY 3000083 (PVC coated C-Head)
SPRING ASSEMBLY - 4-1324
13-1237 1 Shaft
22000155 1 C-Head (PVC coated)
35-0662 1 Screw, Set
43-1239 1 Spring, Compression
55-1265 1 Pin, Drive
63-1238 1 Pin, Retainer
Item Part No. Item Part No.
No. No. Req’d Description No. No. Req’d Description
C-HEAD ASSEMBLY 4-0646 (Non PVC coated C-Head)

Operating Instructions and Parts List Form No. 1000023A
PARTS LIST
Sheet No. 5 of 5
Rev 1 Date: 13 June 2005
A
AVIEW C-C
10
11
12
13
CC
SECTION B-B
B
B
SECTION A-A
1
2
3
4
5
7
8
9
6
15-0007 1 Screw
23-4145 1 Washer, Seal
35-1996 1 Pin, Locater
43-1205 1 Washer
53-1211 1 Wiper
64-0649 1 Body, Ram
73-1214 1 Ring, Backup
85-1263 1 O-Ring
94-1324 1 Spring Assembly
10 5-1269 1 Pin, Drive
11 3-1241 1 Pin
12 3-1242 1 Shaft
13 3-1239 1 Spring
Item Part No. Item Part No.
No. No. Req’d Description No. No. Req’d Description
RAM ASSEMBLY - 4-0648

Operating Instructions and Parts List, Form No. 1000023A, Back sheet 5 of 5
PARTS LIST
12
3
4567
8
9
10
SECTION VIEW
13000083 1 C-Head Assembly
23-1203 1 Screw
34-0645 1 Cylinder
43-1204 1Key
55-1258 1 Lock Washer
64-0648 1 Ram Sub-Assembly
75-0152 1 Screw, Socket Set
810266 1 O-Ring
95-3245 1 O-Ring
10 11032 1 Ring, Retaining
Item Part No. Item Part No.
No. No. Req’d Description No. No. Req’d Description
14-0646 1 C-Head Assembly
23-1203 1 Screw
34-0645 1 Cylinder
43-1204 1Key
55-1258 1 Lock Washer
64-0648 1 Ram Sub-Assembly
75-0152 1 Screw, Socket Set
810266 1 O-Ring
95-3245 1 O-Ring
10 11032 1 Ring, Retaining
Item Part No. Item Part No.
No. No. Req’d Description No. No. Req’d Description
C-HEAD/RAM CYLINDER ASSEMBLY 4-0644 (Non PVC coated C-Head)
C-HEAD/RAM CYLINDER ASSEMBLY 3000084 (PVC coated C-Head)