BP4UCR
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Table 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Table 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TA04583 B Page 1 of 8
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. DO NOT SHORT CIRCUIT THE BATTERY TERMINALS.
5. ALWAYS RECYCLE THE BATTERIES.
6. DO NOT DISCARD BATTERIES INTO DOMESTIC REFUSE
OR WASTE DISPOSAL.
Ni-MH
3
1.1
BATTERY OPERATED
HYDRAULIC CRIMPING TOOL
This “BP4UCR” 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
.
5 6 71 2
1.3
(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 LPA is equal to............66.8 dB (A
The maximum value of the weighted acoustic
displacement pressure
C at the work place L
The acoustic power level emitted by the machine
LWA is equal to...............................................75 dB (A)
1.4
(Directive 2006/42/EC, annexe 1, point 2.2.1.1)
Tests performed in compliance with UNI ENV 25349
and UNI EN 28663 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
1.5
ACOUSTIC NOISE
is....................<130 dB (C)
pCPeak
RISK DUE TO VIBRATION
2
OVERALL VIEW
)
BP4UCR includes the following:
• Battery • Wrist Strap • Spare Battery
• Battery Charger • Carrying Case
1.2
Suitable for installing electric compression connectors
for conductors from 8 AWG up to 300 Cu, 4/0 AL.
Crimping Force Nominal.............................6 Tons
Rated Operating Pressure.........................4,600 psi
Dimensions:
Length..............................................................17.7”
Width.................................................................14.7”
Height.................................................................2.6”
Weight (with battery).....................................6.4 lbs
Motor...........................................................9.6V DC
Battery - direct current..........9.6 V - 3.0 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.
APPLICATION RANGE
Fig. 1
Operating Button
3
Wrist Strap
13
Battery Condition Display
11
8
11
13
3
2
Battery
2
Pressure Release Button
8
TA04583 B Page 2 of 8
2.0
INSTRUCTIONS FOR USE
2.1
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, and the ram fully retracted proceed
as follows:
• Select the appropriate groove or die set for the connector.
(Ref: Check Thomas & Betts instruction sheet for the
connector and make sure die code matches die code of
connector.)
• If using ‘W’ dies refer to section 2.5.
• Insert the conductor in the connector.
• Position the connector between the groove or dies and
ensure the correct location of the crimp. (See connector(s)
instruction sheet for number of crimps.)
PREPARATION (Refer to Figs. 1, 2 & 3)
WARNING
When operating the tool never place hands or other body
parts between the crimping dies or tool jaws.
2.2
Make sure the dies are exactly positioned on desired
crimp point, otherwise reopen dies following instructions
as per Step 2.4 and reposition the connector.
DIE ADVANCEMENT (Refer to Fig. 3)
• Press the operating button (3) to activate the motorpump and advance the ram. To halt the advancement,
release the operating button (3) and the motor will stop.
“W” Style Dies
2
2
Fig. 2
2.4
2.5
RELEASE OF DIES (Refer to Fig. 3)
• By pressing the pressure release button (8) , the ram will
retract and open the tool jaws.
USING “W” STYLE DIES
• Press pins (2) and insert “W” dies into their seats in the
tool jaws.
• To remove, simply press pins (2) and slip dies from the
tool jaws.
8
3
Fig. 3
2.3
• Continue pressing the operating button (3), the ram will
• Continue tool operation until the maximum pressure
• The tool jaws will automatically open as the ram is fully
COMPRESSION (Refer to Fig. 3)
gradually move forward until the tool jaws touch.
relief valve is activated and a “click” is heard.
retracted. To interrupt automatic retraction of the ram,
quickly press the operating button (3).
2.6
• Ensure the ram is fully retracted.
• Push and turn the locking pin (9) clockwise so that it
TOOL JAW REPLACEMENT
(Refer to Fig. 4)
slides out and disengages from the jaw assembly.
• Slide the jaw assembly out from the top
of the tool.
• Insert replacement jaws into the tool and
push the locking pin back into the tool
and jaws.
• Make sure the pin locks by turning it
clockwise until the red index marks are
aligned.
Red Lines
9
TA04583 B Page 3 of 8
Fig. 4
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.
(Refer to Fig. 5)
3.1
BATTERY STATUS
• After releasing the operating button, the residual
battery capacity is automatically displayed for 5
seconds on the indicator (11).
The number of LEDs illuminated indicates the residual
capacity:
LEDs
11
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.
3.2
GENERAL BATTERY & CHARGER USE
Fig. 5
This tool is supplied with a battery charger CFC 120Y and adapter CBA96-144,
which is required for 9.6V batteries (CB9630H). 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 these rules:
• 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 rst 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 100-120V~50-60Hz
Output Voltage 7.2-14.4V
Charging Current 2.4A
Trickle Charge 60mA
Weight 1.1 lbs.
BATTERY
ADAPTER
Fig. 6
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
LED, left-hand, red
Red LED on
Red LED ashing
LED, right-hand, multi-coloured
Green LED on
Green LED ashing
Red/green LED ashing
Red LED on
Red LED ashing
Charger is connected to the supply
and ready for operation
Charger is defective
Charging started
100%
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
TA04583 B Page 4 of 8
(Continued)
Green flashing (right-hand LED): The battery is fully charged and the charger automatically switches over to the trickle-
charge 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)
NI-Cd 2.0 55 min
NI-MH (CB9620H)* 2.0 55 min
NI-MH (CB9630H)* 3.0 85 min
NI-MH (CB1430H) 3.0 85 min
* To charge these batteries use the CBA96-144 adapter (Refer to Fig. 6)
•
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
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:
Maximum Charging Time
CFC120Y
MAINTENANCE
4.1 4.2
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.
4.3
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 and accessories.
Plastic Case: size 19.5 x 14.5 x 5.4 inches, (497 x 370 x 137 mm)
weighs 5lbs. (2.3 kg).
THOROUGH CLEANING UNINTERRUPTED USE
The tool should be allowed to cool down following
a series of uninterrupted, successive uses. If a fully
charged battery becomes exhausted in one session,
wait five minutes before replacing the battery and
continuing use
STORAGE
(Refer to Fig. 7)
.
Fig. 7
TA04583 B Page 5 of 8
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 1-800-284-TOOL (8665).
5.1
17
12
TABLE 1
16
See TABLE 2
3
9
8
5
6
13
1101
2
xxxxxx
11
Serial number of tool
TA04583 B Page 6 of 8
Code Nº
6000577 1 Right+Left Shell 1
2598495 2 CB9630H Battery 1
6000579 3 Operating Button 1
6000584 4 Protection 1
6000591 5 Rod 1
6000593 6 Spring 1
6000580 7 Contact 1
6000581 8 Pressure Release Button 1
6000582 9 Button Reinforcement 1
6000618 10 Mechanical Group (see Table 2) 1
6000586 11 Complete Electrical Circuit 1
6900650 12 3.5 x 16 Screw 6
6000589 13 Wrist Strap 1
6232600 16 TA04584 Label 1
6232500 17 TG. 0704 Label 1
ITEMS
Main
DESCRIPTION QTY
4
7
5.2
TABLE 2
1
67
16
350
11
17
12
4
3
6
8
16
15
320
10
11
3
4
2
65
67
72
64
66
65
360
71
3
2
9
5
69
68
1
27
75
70
63
13
600
24
26
31
18
19
30
17
310
62
77
45
7
500
4
19
18
10
11
400
9
210
7
8
11
220
21
15
17
300
8
9
6
57
14
100
1
250
16
20
15
Code Nº
6000625 11 Rubber Grip 1
6000597 100 Actuating Mechanical Group 1
6000357 100 1 Housing 1
6000358 100 4 Gear 1
6760004 100 8 Ø 2x8 Cylindrical Pin 3
6900008 100 9 M3x6 Screw 2
6000849 100 10 Ø 3 Schnorr Washer 2
6740020 100 11 1/4” Ball 2
6000363 100 15 Gear 3
6402009 100 16 Bearing 1
6402006 100 17
6000328 100 18 Washer 1
6760012 100 19 Cylindrical Pin 2
6000315 100 20 Spacer 3
6000598 100 210 Complete Disc 1
6000359 100 6 Disc 1
6000558 100 7 Balls Support 1
6700080 100 8 Ø 6 Circlip 1
6650136 100 9 Washer 2
6000599 100 200 Complete Cam 1
Main
ITEMS
DESCRIPTION QTY
Washer
6000595 100 250 Complete Motor 1
6000619 300 Complete Hydraulic Group 1
6620122 300 1 Ram 1
6040240 300 10 Back-up Ring 1
6360300 300 11 O-Ring 1
6000560 300 15 Membrane Ring 1
6720072 300 16 Oil Reservoir 1
6300027 300 17 Valve Piston 1
6000561 300 18 Grub Screw 1
6520232 300 19 Valve Spring 1
6620378 300 21 Pumping Ram 1
6000563 300 24 Valve Rod 1
6000575 300 26 Spring Support 1
6000565 300 27 Test Pressure Cap 1
6641027 300 30 Washer 1
6000567 300 31 Setting Valve Locknut 1
6000603 300 45 Pressure Release Lever 1
6000570 300 57 Pumping Ram Return Spring 1
6740100 300 62 5/32” Ball 1
Code Nº
6520160 300 63 Spring 1
6340590 300 64 Grub Screw 1
6520200 300 65 Spring 1
6740120 300 66 7/32” Ball 1
6640205 300 68 D. 4 Schnorr Washer 1
3041046 300 67 Tie 2
6900052 300 69 M4x6 Screw 1
6000602 300 70 Lever Spring 1
6900054 300 71 M4x6 Screw 1
6360022 300 72 O-Ring 1
1
6360125 300 75 O-Ring 1
6641020 300 77 Ø 6 CU Washer 1
6160081 300 310 Body 1
6000697 300 320 Release Group 1
6520240 300 320 1 Spring 1
6000318 300 320 2 Spring Guide 1
6900021 300 320 3 Screw 1
6000849 300 320 4 D. 3 Schnorr Washer 1
6000608 300 320 65 Spring Support 1
6000596 300 350 Reservoir Cap 1
Main
ITEMS
DESCRIPTION QTY
6000588 300 360 Complete Lever Support 1
6000601 300 400 Complete Membrane 1
6900602 300 500 Complete Suction Screw 1
6000620 600 Complete Jaw Support 1
6000621 600 2 Support 1
6000632 600 3 Roll 2
6560200 600 4 Pin Roll 2
6000622 600 5 Jaws Support 1
6000623 600 6 Spring 1
6040564 600 7 Ram Guide Ring 1
6000624 600 8 Pin Grip 1
6000633 600 9 Jaw Locking Pin 1
6700051 600 12 Ø 10 Circlip 1
6900013 600 13 M3x4 Screw 1
6520030 600 14 Ram Return Spring 1
6520601 600 15 Spring 1
6760420 600 16 Cylindrical Pin 1
6900180 600 17 M4x10 Screw 1
TA04583 B Page 7 of 8
5.3
TABLE 3 for JAW CDD6
5
1
3
1
2
4
3
2
6
Code Nº ITEM DESCRIPTION QTY
6000630 1 Rubber Cover 2
6600022 2 Die Retainer Pin 2
6520404 3 Spring 2
6520630 4 Spring 1
6180171 5 M3 Autolock Nut 1
6760085 6 Ø 3x12 Elastic Pin 2
6
5
For parts or service, contact the tool service center at 1-800-284-TOOL (8665).
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 or refund the purchase price. Proof of purchase is required. Misuse or unauthorized
modication 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.
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
TA04583 B Page 8 of 8© 2010 Thomas & Betts. All Rights Reserved.
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