DMC Power Cable Connector Assembly Instructions

DMC Power
Cable Connector Assembly Instructions
Step 1:
CUT AND CLEAN THE END OF CABLE
Confirm that the DMC Power Cable Connector fitting matches the cable size. Also, confirm that the
Swage Tool matches the Cable Connector fitting size. Cut the cable so that the strand ends are even.
Clean an area of 4 inches from the end of the cable by wire brushing (see picture 1). Visually inspect that
all Aluminum Cable Connector fittings to verify that the inside surface is coated with AFC.
Step 2:
ASSEMBLE THE DMC POWER CABLE CONNECTOR FITTING WITH THE CABLE
Slide the connector over the cable until the end of the cable bottoms out. Check to see, through the
inspection hole, if the end of the cable is visible (see figure 1).
Step 3:
ASSEMBLE THE DMC POWER SWAGE TOOL
Mount the Die Block onto the Power Unit and make sure it is locked in place with the pushpin or
set screws. Slide the Power Unit and Head together.
Step 4:
CONNECT THE HYDRAULIC PUMP TO THE POWER UNIT
Connect the DMC Power Swage Tool to the hydraulic pump via the quick disconnect (threaded or pushpull) fitting to the hydraulic hose line. Properly align the Head and the Power Unit such that the face is
flush as shown in picture 2.
Step 5:
PERFORMING A SWAGE
Position the Swage Tool over the DMC Power Cable Connector fitting. Ensure that the Swage Dies’ teeth
are between the Swage Line marks on the DMC Power Cable Connector fitting as shown in figure 1.
Start the Hydraulic Pump to actuate the tool. Swaging is complete when the Die Block makes contact
with the Head and the pressure reaches 10,000 psi. Disengage the Head from the Power Unit once the
Die Block fully retracts.
Step 6:
INSPECT THE SWAGED CONNECTOR FITTING
Use the Inspection Gauge to verify that the swage is good by positioning the Inspection Gauge on the
swaged portion of the fitting as shown in figure 2. If there are no Inspection Gauges available, refer to
table 1 for “Depth of Swage” dimensions for the swage inspection.
REPEAT STEPS 1 THROUGH 6 FOR EACH CABLE CONNECTOR FITTING END.
Visually inspect all Aluminum Cable Connector fittings to verify that the inside surface is coated with
AFC. Copper Cable connectors do not need AFC.
Remove the Swage Dies when dirty and clean the slots with a wire brush to remove the excess buildup. Once cleaned, re-lubricate with DMC Power Swage Lube.
Refer to DMC Power Cable Connector Standard Operating Procedure QWI-DMCP-7.3-002 Rev “-“ for
more detailed information.
DO NOT USE ON ANY OTHER PRODUCT OTHER THAN DMC POWER FITTINGS.
DO NOT OPERATE THE DMC POWER SWAGE TOOL WITHOUT THE HEAD ASSEMBLY.
IMPROPER USE MAY RESULT IN TOOL FAILURE AND/OR SERIOUS INJURY.
14502 S. Figueroa St., CA 90248
Customer Service: (888) SWAGE NOW
www.dmcpower.com
QWI-DMCP-7.3-002 Rev – (Addendum)
Fig. 1
Pic. 1
Cut the cable so that the ends are
even. Clean an area of about 4”
from the end
Pic. 2
gggggffffffggPosition the DMC Power Swage Tool
gggffffffggggmaking sure that the Swage Die teeth
gggfffffggggare aligned with the Swage Lines on
the Cable Connector.
Fig. 2
Table 1
Pic. 3
dddddddffffffdVerify the Swage using the
fffffffffffffffInspection Gauge.
14502 S. Figueroa St., Gardena, CA 90248
Customer Service: (888) SWAGE NOW
www.dmcpower.com gggggggg
QWI-DMCP-7.3-002 Rev – (Addendum)
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