BPI42CR and BPI42300CR Battery Operated Hydraulic Crimping Tool Operating Instruction Manual IMPORTANT: Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Table of Contents 1.0 General Characteristics. 2 2.0 Instructions for Use. 3 3.0 Battery and Charger Use. 4-5 4.0 Maintenance. 5 5.0 Spare Parts List. 6 5.1 Table 1. 7 5.2 Table 2. TA04492 B Page 1 of
1.0 GENERAL CHARACTERISTICS WARNING 1. BEFORE USING THE TOOL, CAREFULLY READ INSTRUCTIONS IN THIS MANUAL. 2. WHEN OPERATING THE TOOL NEVER PLACE HANDS OR OTHER BODY PARTS BETWEEN THE CRIMPING DIES. 3. DO NOT USE IN WATER OR IN THE RAIN. 4. ALWAYS ENSURE CORRECT LATCHING AND SECURITY OF THE TOOL HEAD. 5. DO NOT SHORT CIRCUIT THE BATTERY TERMINALS. 6. ALWAYS RECYCLE THE BATTERIES. 7. DO NOT DISCARD BATTERIES INTO DOMESTIC REFUSE OR WASTE DISPOSAL. 1.3 ACOUSTIC NOISE (Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u) The weighted continuous acoustic pressure level equivalent A at the work place L PA is equal to...66. db (A) The maximum value of the weighted acoustic displacement pressure C at the work place L pcpeak is...<130 db (C) The acoustic power level emitted by the machine L WA is equal to...75 db (A) 1 2 3 4 4 1.1 Ni-MH 5 6 7 BATTERY OPERATED HYDRAULIC CRIMPING TOOL This BPI42CR hydraulic tool is powered by 9.6 V DC Ni-MH battery. The tool is well balanced for optimum control, quiet operation, very little vibration and lightweight construction enabling the operator to hold the tool in one hand while positioning the connector with the other hand. It is equipped with an automatic system that opens the dies once the crimping operation is completed. The residual battery capacity level is automatically displayed after every cycle. BPI42CR includes the following: Battery Wrist Strap Spare Battery Battery Charger Carrying Case BPI42300CR includes the following: Battery Wrist Strap Spare Battery Battery Charger Carrying Case Die Set 1.4 (Directive 2006/42/EC, annexe 1, point 2.2.1.1) Tests performed in compliance with UNI ENV 25349 and UNI EN 2663 part 1st Standards, and under operating conditions more severe than normal, certify that the weighted root mean square in frequency of the acceleration the upper limbs are exposed to for each biodynamic reference axis does not exceed 2.5 m/sec 2 1.5 OVERALL VIEW 27 RISK DUE TO VIBRATION 24 600 1.2 APPLICATION RANGE Suitable for installing electric compression connectors for conductors from AWG up to 300 Cu, 4/0 AL. Crimping Force Nominal...4 Tons Rated Operating Pressure...5600 psi Dimensions: Length...14.6 Width...4.2 Height...2.6 Weight (with battery)...5.3 lbs Motor...9.6V DC Battery - direct current...9.6 V - 2.0 Ah Ni-MH Oil Recommended...AGIP ARNICA 22 or SHELL TELLUS TX22 or equivalent Safety...the tool is provided with a maximum pressure relief safety valve. Fig. 1 3 2 See 3.1 (Fig. 4) 3 Operating Button Pressure Release Button 13 Wrist Strap 24 Upper Die Support Battery Condition Display 27 Lower Die Support 2 Battery 600 Head Complete 13 TA04492 B Page 2 of
2.0 INSTRUCTIONS FOR USE 2.1 PREPARATION (Refer to Figs. 1, 2 & 3) The tool is supplied with the batteries completely discharged; before use, fully charge the batteries using the charger supplied. See section 3.0 The tool can be easily carried using either the handle or wrist strap, see Fig. 1. With the tool at rest, proceed as follows: Select the appropriate die set for the connector. (Ref: Check Thomas & Betts instruction sheet for the connector and make sure color code of die matches color code of connector.) Open the latch (25) and release the upper die holder (24). Insert one die into the upper die holder (24) and one die into the lower die support (27). Close the latch (25). Insert the conductor in the connector. Position the connector between the dies and ensure the correct location of the crimp. (See connector(s) instruction sheet for number of crimps.) Ensure that the latch and upper die holder are fully secured, otherwise damage may occur during tool operation. Fig. 2 24 WARNING When operating the tool never place hands or other body parts between the crimping dies. 27 25 2.2 DIE ADVANCEMENT (Refer to Fig. 3) Press the operating button (3) to activate the motorpump and advance the lower die. To halt the advancement, release the operating button (3) and the motor will stop. Make sure the dies are exactly positioned on desired crimp point, otherwise reopen dies following instructions as per Step 2.5 and reposition the connector. 2.4 HEAD ROTATION For ease of operation, the tool head can be rotated through 10º, allowing the operator to work in the most comfortable position. WARNING Do not attempt to rotate the head when the hydraulic circuit is pressurized. 2.5 RELEASE OF DIES (Refer to Fig. 3) By pressing the pressure release button (), the ram will retract and open the dies. 3 Fig. 3 2.3 COMPRESSION (Refer to Fig. 3) Continue pressing the operating button (3), the ram will gradually move forward until the two dies touch. Continue tool operation until the maximum pressure relief valve is activated and a click is heard. The dies will automatically open until the ram is fully retracted. To interrupt automatic retraction of the ram, quickly press the operating button (3). TA04492 B Page 3 of
3.0 BATTERY AND CHARGER USE The tool is supplied with the batteries completely discharged; before use, fully charge the batteries using the charger supplied. 3.1 3.2 After releasing the operating button, the residual battery capacity is automatically displayed for 5 seconds on the indicator (). The number of LEDs illuminated indicates the residual capacity: 6 LEDs illuminated: Fully Charged 3 LEDs illuminated: 50% capacity 1 LED illuminated: Minimum charge To replace the battery, press the two red buttons at the same time and slide the battery forward. LEDs Fig. 4 This tool is supplied with a battery charger CFC 120Y and adapter CBA96-144, which is required for 9.6V batteries (CB9620H). With the adapter removed, the same charger may be used with the 14.4 V Batteries common to other Thomas & Betts battery operated tools. For optimum battery life, please follow the rules: BATTERY STATUS (Refer to Fig. 4) GENERAL BATTERY & CHARGER USE Use the battery until the automatic residual energy display still has 1-2 red LEDs showing: this means the battery is almost completely discharged and no loss in the life of the battery has been produced. This is particularly important when charging a new battery the first 2-3 times in order to maximize the available energy level. Allow the battery to cool down to ambient temperature prior to recharging. Rest the battery charger for at least 15 minutes between charges. Back of Tool CHARGER SPECIFICATIONS Input Voltage Output Voltage Charging Current 2.4A Trickle Charge Weight Fig. 5 BATTERY ADAPTER 100-120V~50-60Hz 7.2-14.4V 60mA 1.1 lbs. 3.3 OPERATING LOCATIONS The chargers are designed for use in dry areas. All ventilation slots must be kept unobstructed. If possible, keep away from heat sources and out of direct sunlight as ambient temperatures in excess of 35 C may increase charging times considerably. AC SUPPLY CONNECTION Before connecting the charger, check that the AC-supply voltage and frequency are the same as those indicated on the charger. The charger is ready for operation when the power cord is connected to the live AC supply. PUTTING INTO SERVICE AND OPERATION Left-hand, red LED If the charger is connected to the AC supply and the left hand LED goes red, the charger is OK. If the left-hand LED is red and flashing the charger has a fault. Further charging is not possible. CHARGING PROCEDURE (See table on the right.) The battery charger checks the voltage, temperature, short-circuit and polarity of the batteries before charging. The safety elements (bi-metal strip or NTC resistor) are checked via the temperature contact. If the safety elements are OK, the right-hand LED goes green and the charging procedure commences. Charging state detection is a special feature of this charging method. If the right-hand led remains switched off, the internal circuit of the battery either is open or there is a condition of polarity inversion. (Continued on next page) BATTERY CHARGER OPERATION Red LED on Red LED flashing Green LED on Green LED flashing Red/green LED flashing Red LED on Red LED flashing LED, left-hand, red LED, right-hand, multi-coloured 100% Charger is connected to the supply and ready for operation Charger is defective Charging started Battery is full charged The power supply is less than 10,5 V (only for CFC12-24IC) Battery is defective Battery is too hot or too cold TA04492 B Page 4 of
(Continued) Green flashing (right-hand LED): The battery is fully charged and the charger automatically switches over to the tricklecharge mode. The battery can be left indefinitely in the charger without sustaining any damage. Overcharging is impossible. Red flashing (right-hand LED): The safety elements are defective or the battery is too hot or too cold. The battery should be removed from the charger so that it can return to its proper temperature range. Continuous red (right-hand LED): The battery is defective. CHARGING TIMES The following table lists the various charging times (the charging time depends on the depth of discharge). A new or seldom used battery will achieve full power after 5 charge/discharge cycles. Battery Type Nominal capacity (Ah) Maximum Charging Time CFC120V NI-Cd 2.0 55 min NI-MH (CB9620H)* 2.0 55 min NI-MH (CB9630H)* 3.0 5 min NI-MH (CB1430H) 3.0 5 min * To charge these batteries use the CBA96-144 adapter (Refer to Fig. 5) WARNING The left-hand LED flashes red to indicate a charger fault. A charger malfunction has occurred and it is not possible to continue charging. Do not use the charger to charge other batteries. If batteries are new or have not been used for some time, it is quite likely that they will not reach their nominal capacity. This is not a fault and is normal under these circumstances. Full capacity will be reached after about the 5 charge/discharge cycles. The charger monitors the battery-pack temperature. Batteries with temperatures above 65 C or below 5 C will not be charged. The charger is designed to charge both Ni-Cd and Ni-MH batteries: with Ni-MH batteries a more noticeable heating of the cells will occur. This is not a fault. 4.0 MAINTENANCE The tool is completely sealed, and requires very little daily maintenance. Compliance with the following recommendations, should help to maintain the optimum performance of the tool: 4.1 THOROUGH CLEANING Dust, sand and dirt are a danger for any hydraulic device. After every use, the tool must be wiped with a clean cloth taking care to remove any residue, especially close to moveable parts. 4.2 When not in use, the tool should be stored and transported in the plastic case to prevent damage. This case is suitable for storing the tool, the accessories, and die sets. Plastic Case: size 1.3x12.4x4.56 inches, (465x315x6 mm) weighs 3.3lbs. (1,5 kg). STORAGE (Refer to Fig 6) Fig. 6 TA04492 B Page 5 of
5.0 SPARE PARTS LIST When ordering spare parts always specify the following: Code number of item Name of item Type of tool Tool serial number Warranty is void if replaced parts are not Thomas & Betts original replacement parts. For parts or service, contact the tool service center at 1-00-24-TOOL (665). TA04492 B Page 6 of
5.1 TABLE 1 15 See TABLE 2 16 10 1 3 9 5 6 13 17 2 12 xxxxxx Serial number of tool 4 7 ITEMS Code Nº Main 1st Sub 2nd Sub DESCRIPTION QTY 6000577 1 Right+Left Shell 1 25949 2 Battery 1 6000579 3 Operating Button 1 600054 4 Protection 1 6000591 5 Rod 1 6000593 6 Spring 1 600050 7 Contact 1 600051 Pres. Release Button 1 600052 9 Button Reinforcement 1 6000301 10 Mechanical Group 1 600056 Compl. Electr. Circit 1 6900650 12 Screw 6 600059 13 Wrist Strap 1 6232220 15 Label TA0394 1 623255 16 Label TA04490 1 6232500 17 Label T.G. 0704 1 For parts or service, contact the tool service center at 1-00-24-TOOL (665). WARRANTY: Thomas & Betts sells this product with the understanding that the user will perform all necessary tests to determine the suitability of this product for the user s intended application. Thomas & Betts warrants that this product will be free from defects in materials and workmanship for the period stated on the enclosed warranty card. Upon prompt notification of any warranted defect, Thomas & Betts will, at its option, repair or replace the defective product or refund the purchase price. Proof of purchase is required. Misuse or unauthorized modification of the product voids all warranties. Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE WARRANTY CONCERNING THIS PRODUCT, AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE SPECIFICALLY DISCLAIMED. LIABILITY FOR BREACH OF THE ABOVE WARRANTY IS LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO CIRCUMSTANCES WILL THOMAS & BETTS BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. TA04492 B Page 7 of
5.2 TABLE 2 16 4 15 6 3 4 2 69 24 26 31 1 4 19 1 10 1 100 67 16 350 600 25 26 67 2 320 64 65 66 360 71 27 65 72 59 70 1 27 75 310 62 63 45 30 19 17 77 6 57 9 21 9 7 210 220 17 16 20 15 250 21 42 500 400 24 23 5 20 57 17 15 300 22 1 34 1 ITEMS Code Nº Main 1st Sub 2nd Sub DESCRIPTION QTY 6040240 4 Back-up Ring 1 6360300 15 O-Ring 1 6620490 16 Ram 1 6520030 17 Spring 1 6040556 1 Ram Guide Ring 1 670252 27 Die Support 1 6900629 2 Screw 1 6900013 34 Screw 1 6362020 57 Seal 1 652032 59 Spring 2 6000597 100 Actuating Mechanical Group 1 6000357 100 1 Housing 1 600035 100 4 Gear 1 6760004 100 Pin 3 690000 100 9 Screw 2 600049 100 10 Washer 2 6740020 100 Ball 2 6000363 100 15 Gear 3 6402009 100 16 Bearing 1 6402006 100 17 Washer 1 600032 100 1 Washer 1 6760012 100 19 Pin 2 6000315 100 20 Spacer 3 600059 100 210 Complete Disc 1 6000359 100 210 6 Disc 1 600055 100 210 7 Ball Support 1 670000 100 210 Circlip 1 6650136 100 210 9 Washer 2 6000599 100 220 Complete Cam 1 6000595 100 250 Complete Motor 1 6000662 300 Hydraulic Group 1 6000560 300 15 Ring 1 6720072 300 16 Reservoir 1 6300027 300 17 Valve Piston 1 6000561 300 1 Grub Screw 1 6520232 300 19 Spring 1 662037 300 21 Pumping Ram 1 6000563 300 24 Valve Rod 1 6000575 300 26 Spring Support 1 6000565 300 27 Cap 1 ITEMS Code Nº Main 1st Sub 2nd Sub DESCRIPTION QTY 6641027 300 30 Washer 1 6000567 300 31 Lockout 1 6000603 300 45 Pressure Release Lever 1 6000570 300 57 Spring 1 6740100 300 62 Ball 1 6520160 300 63 Spring 1 6340590 300 64 Grub Screw 1 6520200 300 65 Spring 1 6740120 300 66 Ball 7/32 1 3041046 300 67 Tie 2 6640205 300 6 Washer 1 6900052 300 69 Screw M4X6 1 6000602 300 70 Spring 1 6900054 300 71 Screw M4X6 1 6360022 300 72 O-Ring 1 6360125 300 75 O-Ring 1 6641020 300 77 Washer D6 CU 1 616001 300 310 Body 1 6000697 300 320 Release Group 1 6520240 300 320 1 Spring 1 600031 300 320 2 Spring 1 6900021 300 320 3 Screw M3X 1 600049 300 320 4 Washer 1 600060 300 320 65 Spring Support 1 6000596 300 350 Cap 1 60005 300 360 Lever 1 6000601 300 400 Complete Membrane 1 6900602 300 500 Suction Screw 1 66014 600 Complete Head 1 670163 600 1 Head Support 1 6560370 600 20 Pin 2 6520403 600 21 Spring 1 634013 600 22 Grub Screw 1 6520942 600 23 Spring 1 670124 600 24 Die Support 1 6370270 600 25 Latch 1 652042 600 26 Spring 1 6040725 600 42 Circlip 2 6740020 600 5 Ball 1 2010 Thomas & Betts. All Rights Reserved. Thomas & Betts Corporation Memphis, Tennessee www.tnb.com TA04492 B Page of