Thomas & Betts BPI42CR, BPI42300CR User Manual

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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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.

Ni-MH

3

1.1

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

.

5 6 71 2 4 4

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

27

ACOUSTIC NOISE

is....................<130 dB (C)

pCPeak

RISK DUE TO VIBRATION

2

OVERALL VIEW

24

600

)

BPI42300CR includes the following:

• Battery • Wrist Strap • Spare Battery

• Battery Charger • Carrying Case • Die Set

1.2

Suitable for installing electric compression connectors
for conductors from 8 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.

TA04492 C Page 2 of 8

APPLICATION RANGE

Fig. 1

Operating Button

3

Wrist Strap

13

Battery Condition Display

11

Battery

2

8

3

2

Pressure Release Button

8

Upper Die Support

24

Lower Die Support

27

Head Complete

600

11

See 3.1

(Fig. 4)

13

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, 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.

2.2

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.

DIE ADVANCEMENT (Refer to Fig. 3)

• Press the operating button (3) to activate the motor-

pump and advance the lower die. To halt the
advancement, release the operating button (3) and the
motor will stop.

PREPARATION (Refer to Figs. 1, 2 & 3)

24

27

25

Fig. 2

WARNING

When operating the tool never place hands or other body

2.4

• For ease of operation, the tool head can be rotated
through 180º, allowing the operator to work in the most
comfortable position.

parts between the crimping dies.

HEAD ROTATION

WARNING

Do not attempt to rotate the head when the hydraulic

circuit is pressurized.

8

3

Fig. 3

2.3

• Continue pressing the operating button (3), the ram will

• Continue tool operation until the maximum pressure

• The dies will automatically open until the ram is fully

COMPRESSION (Refer to Fig. 3)

gradually move forward until the two dies touch.

relief valve is activated and a “click” is heard.

retracted. To interrupt automatic retraction of the ram,
quickly press the operating button (3).

2.5

RELEASE OF DIES (Refer to Fig. 3)

• By pressing the pressure release button (8) , the ram will
retract and open the dies.

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