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Operating Instructions
for BAIR22-6
AIR-POWERED CRIMPING TOOL
1.0 GENERAL INFORMATION
1.1 Description
1.2 Shure Stake
1.3 Safety
1.4 Purpose of this Manual
1.5 Tool Warranty
1.6 Identication
1.7 Specication
2.0 IMPORTANT SAFETY INFORMATION
2.1 Safety Alert Symbol
2.2 Warnings & Cautions
3.0 OPERATION
3.1 Set up Tool
3.2 Die Installation
3.3 Tool Operation
3.4 Preparing Cable
3.5 Crimping Cable
®
Mechanism
....................................................... 4 & 5
....................................... 2
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Table of Contents
Page
.........................3
4.0 MAINTENANCE
4.1 Each Operating Day
4.2 Monthly
5.0 TROUBLESHOOTING
5.1 Table 1
6.0 CALIBRATION VERIFICATION
6.1 Safety
6.2 Visual Inspection
6.3 Gaging Procedure
6.4 Gaging Tables
.....................................................5
Page
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GENERAL INFORMATION1.0
DESCRIPTION1.1
The BAIR22-6 Air-powered Crimping Tool is a bench
mounted, Sta-Kon
terminals on 22 AWG through 6 AWG wire using
appropriate dies. The complete tool consists of a
pneumatic crimping tool, foot switch with Shure
®
Stake
mechanism, and a lter/regulator/lubricator
assembly. All connecting hoses are included to
operate this tool.
NEVER EXCEED 100 PSI.
®
crimping tool intended to crimp
1.2 SHURE STAKE® MECHANISM
The Shure Stake® mechanism incorporated in this
tool is a pneumatic logic circuit designed to assure
that the crimping tool will see a minimum of 80 psi.
If air pressure falls below 80 psi, the ram will not
retract until full pressure is restored, even if the foot
pedal is released.
1.3
Safety is essential in use and maintenance of
Thomas & Betts tools and equipment. This manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
SAFETY
1.6
IDENTIFICATION
1. Die Mounting Screws
2. Die Mounting Dowel Pins (As Needed)
3. Brass Lock Screw
4. Spring Loaded, Movable Upper Die Support
5. Fixed Lower Die Support
All specications are nominal and may change as
design improvements occur. Thomas & Betts shall
not be liable for damages resulting from
misapplication or misuse of its product.
3
4
1
1.4
PURPOSE OF THIS MANUAL
This manual is intended to familiarize all personnel
with the safe operation and maintenance procedures
for the following Thomas & Betts tool:
BAIR22-6 Air-powered Crimping Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge.
TOOL WARRANTY1.5
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 notication of any
warranted defect, Thomas & Betts will, at its option, repair or replace the
defective product. Misuse, misapplication or modication of Thomas & Betts
products immediately 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.
2
FIGURE 1
1.7 SPECIFICATION
Crimping Tool
Length................................................. 12" (305 mm)
Width ....................................................8" (203 mm)
Depth .................................................... 8" (203 mm)
Mass/Weight........................................17 lb (7.9 kg)
Crimping Capacities
Maximum Crimping Force
Normal Operating Pressure
...1.8 tons@100 psi (16 kn)
......................... 85-90 psi
WARNING
NEVER EXCEED 100 PSI
5
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IMPORTANT SAFETY INFORMATION2.0
SAFETY ALERT SYMBOL2.1
This symbol is used to call your
attention to hazards or unsafe
practices which could result in an
injury or property damage. The
signal word, dened below,
indicates the severity of the
hazard. The message after the signal word provides
information for preventing or avoiding the hazard.
WARNING
Hazards which, if not avoided, COULD result in severe
injury or death.
CAUTION
DANGER
Immediate hazards which, if not avoided, WILL result in
severe injury or death.
WARNINGS & CAUTIONS2.2
WARNING
Read and understand all of the
instructions and safety information in
this manual before operating or
servicing this tool.
Failure to observe this warning could
result in severe injury or death.
WARNING
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
Hazards or unsafe practices which, if not avoided, MAY
result in injury or property damage.
WARNING
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
WARNING
Pinch points:
Keep hands away from the crimping
head when crimping.
Failure to observe this warning could
result in severe injury or death.
WARNING
Do not use solvents or ammable
liquids to clean the crimping tool.
Solvents or ammable liquids could
ignite and cause serious injury or
property damage.
CAUTION
Do not perform any service or maintenance other
than as described in this manual. Injury or damage to
the tool may result.
Failure to observe this precaution may result in injury
or property damage.
WARNING
An incomplete crimp can cause a re.
• Use proper die, connector, and cable
combinations. Improper combinations can
result in an incomplete crimp.
•The tool will cycle completely to indicate a
successful crimp. If tool does not cycle
completely, crimp is unsuccessful.
Failure to observe these warnings could result in
severe injury or death.
NOTE:
when necessary.
Keep all decals clean and legible, and replace
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OPERATION3.0
SET UP TOOL3.1
The tool is shipped fully assembled (less dies) with
foot switch attached.
1. Remove tool and lter/regulator/lubricator
assembly from shipping container.
2. Position the tool on a workbench or table
3. Position the foot switch on the oor.
4. Connect the foot pedal air inlet line to the
lter/regulator/lubricator assembly outlet and
main air supply to lter/regulator/lubricator
assembly inlet.
NOTE: Do not add airline extensions between
the foot pedal and lter/regulator/lubricator
assembly. This will prevent line pressure drops.
NOTE: Cylinder and pneumatic components are
designed to operate without lubrication.
If you choose to lubricate, use a quality grade,
non-detergent, SAE #10 parafn base oil.
Rate of lubrication should not exceed one drop
per 100 crimping cycles.
DIE INSTALLATION3.2
1. Disconnect air supply
2. Lift spring loaded upper die support to maximum
height, and lock in place by tightening brass lock
screw.
3. Install die nest into lower support and die
indentor into upper die support using screws
provided. Screws should be lightly hand
tightened at this time.
NOTE: Some dies require use of dowel pins
combined with the screws. To properly install
these types of dies, remove upper & lower die
supports from tool. Place the die supports in a
vise. Install the appropriate dies into the
supports and install the supplied dowel pins in
place along with screws. Re-Install the
dies/supports and proceed with step 4.
4. Loosen brass lock screw allowing the spring
loaded upper die support to descend so that die
indentor and nest will engage and align. Securely
tighten screws so that dies will not move within
support blocks.
5. Connect air supply.
TOOL OPERATION3.3
1. To operate the tool properly, it is essential to
depress and hold the foot pedal down until the
tool cycles completely. This assures a sustained
volume of air in the cylinder at full pressure to
complete the crimp.
2. The tool is equipped with a spring loaded upper
die support which can be set either in the “up”
position permitting the dies to open after every
crimp, or in the “down” position allowing the
spring loaded upper die support to “hold” the
connectors in place prior to and after crimping.
For normal use, the “down” position is preferred.
To change to “up” operating mode raise upper
die support fully and tighten brass lock screw.
PREPARING CABLE3.4
Follow the terminal manufacturer's instructions for
appropriate cable strip length.
WARNING
• Inspect tool and dies before use. Replace any
worn or damaged parts. A damaged or
improperly assembled tool can break and strike
nearby personnel.
• Failure to observe this warning could result in
severe injury or death.
Do not attempt to connect the tool to an
•
energized air line.
• Disconnect tool from air supply when servicing
or changing dies.
• Avoid accidental starting. Remove foot from
foot switch when not operating the tool.
CAUTION
• Do not operate the tool without dies. Damage
to the ram or crimping head can result.
• Never exceed 100 psi operating pressure.
• Use this tool for manufacturer's intended
purpose only
Failure to observe these precautions may result in
injury or property damage.
.
WARNING
Wear eye protection when
operating or servicing this tool.
Failure to wear eye protection
could result in serious eye injury
from ying debris or hydraulic oil.
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3.0 OPERATION.....Continued
CRIMPING CABLE3.5
1. Insert the properly assembled connector into the
crimping head die nest.
2. Depress and hold the foot pedal until tool cycles
completely. Repeat Step 2 for the next crimp
(see Figure 2).
NOTE: If it is necessary to retract the ram before
a crimping cycle is complete, Disconnect air
supply.
WARNING
An incomplete crimp can cause a re.
• Use proper die, connector, and cable
combinations. Improper combinations can
result in an incomplete crimp.
• The tool will cycle completely to indicate a
successful crimp. If tool does not cycle
completely, crimp is unsuccessful.
Failure to observe these warnings could result in
severe injury or death.
Sta-Kon® Terminals
One crimp required.
Non Insulated Insulated
Crimp
Crimp
Sta-Kon® Splices
Two crimps required, one crimp on each side.
Non Insulated
Crimp
Crimp
Insulated
FIGURE 2
Crimp
Crimp
4.0 MAINTENANCE
EACH OPERATING DAY4.1
Before use:
1. Inspect dies for wear or damage such as cracks,
gouges, or chips.
2. Inspect the tool for damage or air leaks. If
damage is detected, return the tool to an
authorized Thomas & Betts service center for
inspection,
3. Ensure all fasteners are properly tightened.
4. Make sure spring loaded upper die holder is free
to travel without binding. Lubricate ram if
needed. If using tool with the die holder in the
“up” position, make sure it is raised fully and
locked in place with brass screw.
After use:
1. Wipe all tool surfaces clean with a damp cloth
and mild detergent. IMPORTANT: See warning
located in Step 4.2.
1-800-284-TOOL (8665).
Before use:
Thoroughly clean all surfaces.
MONTHLY4.2
WARNING
Do not use solvents or ammable
cleaners to clean the crimping tool
body. Solvents could ignite,
causing serious injury or property
damage.
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5.0 TROUBLESHOOTING
TABLE 15.1
Problem Probable cause Probable Remedy
Tool is inoperative.
Dies stop during
operation.
For parts or service, contact Thomas & Betts tool service center at 1-800-284-TOOL (8665).
Insufcient air pressure
Tool components worn or damaged.
Air pressure has fallen below 80 psi.
Tool component worn or damaged.
Ensure air supply of 85-90 psi to tool.
Return tool to an authorized Thomas & Betts
service center.
Increase air supply. Press foot pedal to
complete stroke.
Return tool to an authorized Thomas & Betts
service center.
6.0 CALIBRATION VERIFICATION
SAFETY6.1
NOTE: Calibration verication procedure should be
performed whenever the tool is damaged or damage
is suspected.
WARNING
This tool is equipped with the
SHURE STAKE
compelling mechanism.
Keep ngers clear of die nest
during gaging procedure.
VISUAL INSPECTION6.2
Tool must be free of cracks, sharp edges and other
obvious imperfections that may affect performance
of the tool. Nest area must be free of burrs, dents or
scratches.
TABLE 2
DIE2001 GAGING REQUIREMENTS
NEST
RED .100 – .103 #22 – #18 AWG
BLUE .117 – .120 #16 – #14 AWG
YELLOW .149 – .152 #12 – #10 AWG
GAGING
MIN. – MAX.
WIRE SIZE
DIE2500 GAGING REQUIREMENTS
NEST
RED .080 – .088 #22 – #18 AWG
BLUE .091 – .099 #16 – #14 AWG
YELLOW .119 – .127 #12 – #10 AWG
®
full stroke
TABLE 5
GAGING
MIN. – MAX.
GAGING TABLES6.4
DIE2002 GAGING REQUIREMENTS
NEST
A .062 – .067 #22 – #18 AWG
B .084 – .089 #16 – #14 AWG
C .110 – .115 #12 – #10 AWG
WIRE SIZE
GAGING
MIN. – MAX.
TABLE 3
GAGING PROCEDURE6.3
NOTE: Wipe die nest before gaging.
1. Cycle tool until dies bottom.
2. Using gage pins, insure that each nest meets the
gaging requirements as specied in TABLE 2, 3,
4, 5, or 6 per the corresponding die.
UPON SUCCESSFUL COMPLETION OF THE
ABOVE PROCEDURE, THE PREVIOUS
CALIBRATION OF THE TOOL IS VERIFIED
NOTE: If tool fails any of the above tests, do not
attempt repair or adjustment. Call the nearest
Thomas & Betts Tool Service Center to arrange for
repair service. Any change, modication or alteration
of the tool or use by the customer in a manner other
than as specied by Thomas & Betts shall void all
warranties express or implied and the customer shall,
therefore, assume all liability for any damage or injury
caused by said change, modied or altered tool or
improper usage or such tool.
TABLE 4
DIE2007 GAGING REQUIREMENTS
WIRE SIZE
NEST
RED .190 – .196 8 AWG
BLUE .212 – .218 6 AWG
TABLE 6
DIE2005 GAGING REQUIREMENTS
NEST
B .083 – .089 #16 – #14 AWG
C .118 – .124 #12 – #10 AWG
D-E .176 – .181 #8 – #6 AWG
GAGING
MIN. – MAX.
WIRE SIZE
GAGING
MIN. – MAX.
WIRE SIZE
© 2014 Thomas & Betts. All Rights Reserved. Thomas & Betts Corporation • Memphis, Tennessee • www.tnb.com
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