Stanley IBC600 User Manual

IBC600

6-TON IN-LINE

CRIMPING TOOL

USER MANUAL

Safety, Operation and Maintenance

© 2017 STANLEY Black & Decker, Inc.

New Britain, CT 06053

U.S.A.

81140 1/2018 Ver. 2

TABLE OF CONTENTS

SAFETY SYMBOLS ...............................................................................................................................................4

SAFETY PRECAUTIONS .......................................................................................................................................5

TOOL ANATOMY ....................................................................................................................................................6

SPECIFICATIONS & ACCESSORIES ....................................................................................................................7

OPERATION ...........................................................................................................................................................8

STANLEY CRIMP SOFTWARE ..............................................................................................................................11

TROUBLESHOOTING ...........................................................................................................................................16

IBC600 PARTS ILLUSTRATION ............................................................................................................................17

IBC600 PARTS LIST ..............................................................................................................................................18

IBC600 HYDRAULIC BODY ILLUSTRATION ........................................................................................................19

IBC600 HEAD UNIT ILLUSTRATION .....................................................................................................................20

92821 CRIMPING JAW ILLUSTRATION................................................................................................................21

92822 CRIMPING JAW ILLUSTRATION................................................................................................................22

92823 CRIMPING JAW ILLUSTRATION................................................................................................................23

To ll out a product warranty validation form and for information on your warranty,

visit www.stanleyinfrastructure.com and select the Company tab > Warranty.

Note: The warranty validation record must be submitted to validate the warranty.

SERVICING: This manual contains safety, operation and routine maintenance instructions. STANLEY Infrastructure
recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized

and certied dealer. Please read the following warning.

SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR

SERVICE OF THIS TOOL.

REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN

AUTHORIZED AND CERTIFIED DEALER.

For the nearest certied dealer, call STANLEY Infrastructure at [phone] and ask for a Customer Service Representative.

IBC600 User Manual ◄ 3

SAFETY SYMBOLS

Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.

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.

This safety alert and signal word indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.

This safety alert and signal word indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.

This safety alert and signal word indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoided,

may result in property damage.

This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.

This signal word indicates a situation which, if not avoided, may result in damage
to the equipment.

Always observe safety symbols. They are included for your safety and for the protection of the tool.

LOCAL SAFETY REGULATIONS

Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and
maintenance personnel.

4 ► IBC600 User Manual

SAFETY PRECAUTIONS

Tool operators must comply with precautions given in this
manual and on the stickers attached to the tool.

These precautions are given for your safety. Review them

carefully before operating the tool.

Supervising personnel should develop additional precautions

relating to the specic work area and local safety regulations.

Place the added precautions in the space provided on page

4.

The IBC600 6-Ton In-line Crimping Tool will provide safe
and dependable service if operated in accordance with

the instructions in this manual. Read and understand this

manual and stickers attached to the tool before operation.
Failure could result in injury or tool damage.

• Use the tool in a work area without bystanders.

• Do not operate the tool unless thoroughly trained or
under the supervision of an instructor. Establish a training
program for all operators to ensure safe operation.

• Always wear safety equipment such as eye protection,
ear protection, head protection and safety shoes at all

times when operating the tool. Use gloves if necessary.

• The operator must be familiar with all prohibited work
areas such as excessive slopes and dangerous terrain

conditions. Ensure that your footing is rm and you are

in balance at all times.

• Do not inspect, clean or replace tool jaws while the
battery is connected. Accidental engagement of the tool

can cause serious injury.

• Do not operate a damaged, improperly adjusted or
incompletely assembled tool.

• Never wear loose clothing that can become entangled in

the working parts of the tool.

• Keep all parts of your body away from pinch points. Long
hair or loose clothing can become drawn into the tool.

• To avoid personal injury or equipment damage, all tool
repair, maintenance and service must be performed by
an authorized service center.

• Never use the tool in the vicinity of ammable materials
or gases.

• Do not use the tool or charge the tool battery in an
explosive atmosphere.

• Cutting or severing of body parts is possible if proper

procedures are not followed.

• Do not use the tool, battery or battery charger for

purposes other than what is described in this manual.

• Always keep critical tool markings, such as labels
and warning stickers, legible. Contact STANLEY for

replacement labels.

• Do not use the tool while under the inuence of drugs
or alcohol.

• Do not use accessories or attachments other than those
recommended by STANLEY.

BATTERIES

• Only charge batteries using a STANLEY recommended
battery charger.

• Do not store batteries with metal objects, such as coins,

nails or keys. Fire can result if battery terminals are

shorted.

• Do not charge a damaged battery. Recycle and replace

damaged batteries with batteries recommended by

STANLEY.

• Do not incinerate or dispose of batteries in the garbage.
Recycle the batteries.

• Do not expose the battery to temperatures over 265°F.
Batteries may explode at high temperatures.

• Leakage of liquid from the battery may occur under

extreme use or high temperatures. If battery liquid gets
on your skin:

1. Wash quickly with soap and water.

2. If the liquid gets in your eyes, ush your eyes

with clean water for 10 minutes. Seek medical

attention immediately.

• Never open the battery.

BATTERY CHARGER

• Do not use the battery charger if the cord is damaged.

• Do not place the charger, or set items on or near the

charger, in such a way as to block airow to the charger.

• Do not use the charger with an extension cord unless
absolutely necessary. Use a cord with the proper wire

size for its length, as described in Table 1.

Length of Cord (Feet) 25 50 100 150

Wire Size (AWG) 18 18 18 16

Table 1: Extension Cord Wire Size

• Do not open the charger or attempt to modify it in any

way.

• Disconnect the charger from power before attempting
to clean it.

• Do not connect the charger to a transformer or engine
generator.

IBC600 User Manual ◄ 5

TOOL ANATOMY

WHAT IS THE IBC600?

The IBC600 is a battery powered 6-Ton in-line crimping tool with interchangeable crimping jaws. IBC600 is capable of
crimping copper and aluminum connectors to 500 MCM and HTAPS to 4/0-4/0. The InteLED gives real time feedback

to the operator and alerts them to a possible bad crimp.

Crimping Jaws

Crushing Risk

Decal

DO NOT put ngers, hands or other body parts between

the jaws. Serious injury will result!

InteLED

Trigger Lock

Trigger

Pressure Release

Pin Lock

Tool Identication &

Warning Decal

USB Port

6 ► IBC600 User Manual

Battery

SPECIFICATIONS & ACCESSORIES

SPECIFICATIONS

Crimping Force .....................................................................................................................................6 Tons (53 kN)

Tool Cycle Time ........................................................................................................................................4.5 seconds

Crimping Capacity ...................................................................................Copper/Aluminum connectors to 500 MCM

HTAPS to 4/0-4/0

Battery Type ........................................................................................DeWalt 20V Max (2 Amp/hour or 5 Amp/hour)

Estimated Crimps per Charge ........................................................................... 200 (2 Amp/hour), 450 (5 Amp/hour)

Tool Weight

with 2 Amp/hour battery ............................................................................................................................7.15 Lbs.

with 5 Amp/hour battery ............................................................................................................................7.70 Lbs.

Tool Length ..................................................................................................................18.8 Inches (2 Amp/hour batt.)

19.6 Inches (5 Amp/hour batt.)

Maintenance Interval ..................................................................................................................Every 30,000 Cycles

ACCESSORIES

D3/O Jaw ........................................................................................................................................................... 92821

(Accepts standard “W” dies)

D3/BG Jaw ........................................................................................................................................................92822

(Accepts standard “W” dies)

Kearney/BG Jaw................................................................................................................................................92823

(Accepts Kearney and “W” dies)

2 Amp/hour DeWalt 20V Max Battery ............................................................................................................ DCB203

5 Amp/hour DeWalt 20V Max Battery ............................................................................................................ DCB205

5 Amp/hour DeWalt 20V Max Battery 2-pack ............................................................................................. DCB205-2

120V AC Charger ...........................................................................................................................................DCB115

12V DC Charger .............................................................................................................................................DCB119

Note: Only use battery chargers recommended by STANLEY.

Bucket Bag ......................................................................................................................................................... BB01

IBC600 User Manual ◄ 7

CHARGE BATTERY

OPERATION

Battery Charging

Battery Charged

Hot/Cold Delay

INSTALL CRIMPING JAW AND BATTERY

DO NOT install or change crimping jaws while the battery
is connected to the tool. Disconnect the battery BEFORE

installing or changing crimping jaws.

2

1

3

1. Pull back the pin lock to eject the jaw pin.

2. Insert the crimping jaw and lock the jaw pin.

8 ► IBC600 User Manual

3. Insert the battery pack.