Thomas & Betts BPLT62BSCR Installation Manual

Page 1

BPLT62BSCR and BPLT62500BSCR

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 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 3

5.0 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . 5

5.1 Table 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5.2 Table 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TA03943 D Page 1 of 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, KEEP HANDS AND OTHER BODY PARTS AWAY FROM THE DANGER ZONE.

3. DO NOT USE IN WATER OR IN THE RAIN.

4. ALWAYS ENSURE CORRECT LATCHING AND SECURENESS OF THE TOOL HEAD.

5. DO NOT SHORT THE BATTERIES.

6. ALWAYS RECYCLE THE BATTERIES.

7. DO NOT DISCARD BATTERIES INTO DOMESTIC REFUSE OR WASTE DISPOSAL.

Ni-MH

1.1

BATTERY OPERATED

HYDRAULIC CRIMPING TOOL

This “BPLT62BSCR” hydraulic tool is powered by 14.4 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. The tool has a two speed operation which provides automatic shifting from a rapid ram advance mode to a slow powerful crimping mode. The residual battery

capacity level is automatically displayed after every cycle.

BPLT62BSCR Includes the following:

• Battery • Wrist Strap • Tool Strap

• Spare Battery • Battery Charger • Carrying Case

BPLT62500BSCR Includes the following:

• Battery • Wrist Strap • Tool Strap

• Spare Battery • Battery Charger • Die Set

• 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...............

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............................................85,3 dB (A)

1.4

(Directive 2006/42/EC, annexe 1, point 2.2.1.1)

Test carried out in compliance with the indications

contained in UNI ENV 25349 and UNI EN 28662

part 1st Standards, and under operating conditions much more severe than those normally found, 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

75 dB (A)

is....................

pCPeak

<130 dB (C)

RISK DUE TO VIBRATION

OVERALL VIEW

1.2

Suitable for installing electric compression connectors for

conductors from 8 AWG up to 500 MCM CU, 350 MCM AL.

Crimping Force Nominal................................6 Tons

Rated Operating Pressure..........................8600 psi

Dimensions:

Length..............................................................11.7”

Width..................................................................3.7”

Height...............................................................11.9”

Weight (with battery)......................................8.8 lbs

Motor.........................................................14.4V DC

Battery - direct current.........14.4 V - 3.0 Ah Ni-MH

Oil Recommended..................AGIP ARNICA 32 or

SHELL TELLUS TX32 or equivalent

Safety...............the tool is provided with a

maximum pressure relief safety valve.

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APPLICATION RANGE

201

Fig. 1

Operating Button

Wrisp Strap

Battery Capacity Indicator

Battery

Pressure Release Lever

201

Head

Ring for Shoulder Strap

Shoulder Strap

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2.0

INSTRUCTIONS FOR USE

2.1

The tool can be easily carried using either the handle or shoulder strap (T) attached to the rings (R), see Fig. 1 on page 2.

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 (41) and release the upper die holder (42).

•

• Insert one die into the upper die holder (42) and one

die into the lower die support (49).

• Close the latch (41).

• Insert the conductor in connector.

• Position the connector between the dies and ensure

the correct location of the crimp. (See connectors 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

DIE ADVANCEMENT (Refer to Fig. 3)

• Press the operating button (10) to activate the motor-pump and advance the lower die. To halt the advancement, release the operating button (10) and the motor will stop.

Make sure the dies are exactly positioned on desired crimp point, otherwise re-open dies following instructions as per Step 2.5 and position the connector again.

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

Fig. 2

WARNING

When operating the tool, keep hands and other body parts

2.4

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

away from the danger zone.

HEAD ROTATION

WARNING

Do not attempt to rotate the head when the hydraulic

circuit is pressurized.

201

Fig. 3

2.3

• By keeping operating button (10) pressed, the motor continues to operate: the ram will gradually move forward until the two dies touch.

• It is recommended to continue pumping until the

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

• The motor will continue to operate after the maximum pressure relief valve has activated. No further crimping force is applied, the oil is bypassed and returned to reservoir.

COMPRESSION

2.5

• By pressing the pressure release lever (201) located below operating button (10), the ram will retract and open the dies.

RELEASE OF DIES

DANGER

DO NOT USE THIS TOOL ON OR

NEAR ENERGIZED CONDUCTORS

WITHOUT PROPER PERSONAL

PROTECTIVE EQUIPMENT.

FAILURE TO OBSERVE THIS

WARNING COULD RESULT IN SEVERE

INJURY OR DEATH.

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3.0

The tool is supplied with the batteries completely discharged; before use, fully charge the batteries using the charger supplied.

BATTERY USE

3.1

BATTERY STATUS (Refer to Fig. 4)

• After releasing the operating button, the residual battery capacity is automatically displayed for 5 seconds on the indicator (15).

The number of LEDs illuminated indicates the residual capacity:

10 LEDs illuminated: Fully Charged 5 LEDs illuminated: 50% capacity 1 LED illuminated: Minimum charge

When replacing the battery, press the two points marked with the word “PUSH” at the same time, remove

the ﬂat battery from its housing and insert the new one.

Fig. 4

4.0

MAINTENANCE

3.2

3.3

USING THE BATTERY CHARGER

Carefully follow the instructions in the battery charger manual.

USING BATTERIES

In order to use the batteries correctly, please follow these rules:

• Use the battery until the automatic residual energy

display still has 1-2 LEDs showing: this means the battery is almost completely discharged and no loss in the life of the battery has been produced.

• Be particularly careful 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.

The tool is robust, completely sealed, and requires very little daily maintenance. Compliance with the following points, should help to maintain the optimum performance of the tool:

4.1

Dust, sand and dirt are a danger for any hydraulic device. Every day, after use, the tool must be wiped with a clean cloth taking care to remove any residue, especially close to pivots and moveable parts. Protect the tool from rain and

moisture. Water will damage the tool and battery.

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 up to 21 die sets and pre-prepared compression connectors.

Plastic Case: size 24.1x16.2x5.1 inches, (543x412x130 mm) weighs 5 lbs. (2,3 kg).

THOROUGH CLEANING

STORAGE

(Refer to Fig 5)

Fig. 5

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5.0

SPARE PARTS LIST

BPLT62BSCR

Spare parts kit code no. 6000057 includes items marked “K” in table, available on

request.

When ordering spare parts always specify the following:

• Code number of item

• Name of item

• Type of tool

• Tool serial number

The Guarantee is void if parts are not Thomas & Betts original replacement parts.

For parts or service, contact the tool service center at 1-800-284-TOOL (8665).

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5.1

TABLE 1

See TABLE 2

xxxxxx

Tool Serial Number

Code Nº

6000512 01 – – Electric Circuit+Shells 1 6000658 01 01 – Right + Left Shell 1 6900646 01 03 – Screw 2,2x 6,5 2 6760144 01 04 – Pin D.3x 22 2 6000240 01 05 – Compl. Electr. Circuit 1 6000649 02 – – Screw 2,2 x 4,5 2 6900655 03 – – Screw 3,5x 38 3 6000304 04 – – Ring 2 6040427 05 – – Ring 1 6000544 07 – – Mechanical Group 1 6900650 08 – – Screw 1 6760149 09 – – Pin d.3x 16 1 6000237 10 – – Button 1 6520531 11 – – Spring 2 6900651 13 – – Screw 3,5x 22 8 6000447 14 – – Wrist 1 6232095 15 – – Label Strap 1 8502001 16 – – Battery 1 6232497 17 – – Label Strap 1

Main 1st Sub 2nd Sub

ITEMS

DESCRIPTION QTY

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5.2

TABLE 2 (Item 07 from table 1)

205

200

201

203

204

202

Code Nº

6520532 02 – – Spring 1 – 6620113 03 – – H.S. RAM 1 – 6620109 04 – – Pumping Ram 1 – 6720073 05 – – Reservoir 1 – 6000330 08 – – Spacer 1 – 6040080 12 – – Back-Up Ring 1 K 6360022 13 – – O-Ring 1 K 6360260 14 – – O-Ring 1 K 6800040 15 – – Cap 1 – 6361999 30 – – Seal 1 K 6520601 33 – – Spring 1 K 6760230 34 – – Pin 1 – 6520030 35 – – Spring 1 – 6361900 36 – – O-Ring 1 – 6040556 37 – – Ram Guide Ring 1 – 6362020 38 – – Seal 1 – 6340590 43 – – Grub Screw 2 6520200 44 – – Spring 2 K 6740120 45 – – Ball 3 K 6900629 48 – – Screw 1 –

Main 1st Sub 2nd Sub

ITEMS

DESCRIPTION QTY

6780252 49 – – Die Support 1 – 6620490 50 – – Ram – – 6360161 52 – – O-Ring 1 K 6900090 53 – – Screw 4 6360140 54 – – O-Ring 1 K 6600100 55 – – Dowel 1 6520520 56 – – Spring 1 K 6520160 57 – – Spring 2 K 6740100 58 – – Ball 2 K 6641020 59 – – Washer 2 K 6900601 60 – – Suct. Screw 2 – 6900181 61 – – Screw M4x 10 1 – 6520382 62 – – Die Stop Spring 2 – 6362098 63 – – Seal 1 – 6895049 64 – – Compl. Valve 1 – 6900640 65 – – Press. Release Screw 1 – 6900306 67 – – Screw 1 – 6635011 68 – – Pin 1 K 6520861 69 – – Spring 1 K 6640205 72 – – Washer 4 K

Code Nº

6250084 73 – – Tie 1 – 6362021 74 – – Seal 2 K 6362007 75 – – Seal 1 K 6340720 76 – – Grub Screw 1 – 6020020 77 – – Pin 1 – 6361881 78 – – O-Ring 1 K 6360120 79 – – O-Ring 1 K 6000385 80 – – Bush 1 – 6860012 200 – – Compl. Head 1 – 6780150 200 39 – Head Support 1 – 6520482 200 40 – Spring 1 – 6370270 200 41 – Latch 1 – 6780133 200 42 – Upper Die Holder 1 – 6520403 200 45 – Spring 1 – 6740020 200 83 – Ball 1 – 6520942 200 84 – Spring 1 – 6340138 200 85 – Grub Screw 1 – 6560370 200 86 – Pin 2 – 6040725 200 87 – Circlip 2 –

Main 1st Sub 2nd Sub

ITEMS

DESCRIPTION QTY

6440117 201 – – Pres. Release Lever 1 – 6000523 202 – – Complete Housing 1 – 6760001 202 11 – Pin 2 – 6000310 202 16 – Comp. Motor 1 – 6000328 202 17 – Washer 1 – 6900181 202 18 – Screw 4 – 6000364 202 19 – Gear 4 – 6000363 202 20 – Gear 3 – 6000323 202 21 – Gear 1 – 6000196 202 22 – Gear 1 – 6000315 202 23 – Washer 7 – 6700520 202 26 – Circlip 1 – 6000392 202 29 – Bearing 1 – 6040682 202 32 – Ring 1 – 6220198 202 47 – Spacer 2 – 6640205 202 70 – Washer 4 – 6040686 202 71 – Ring 1 – 6000336 202 203 – Eccentric 1 – 6000525 202 204 – Housing 1 – 6160054 205 – – Body 1 –

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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. 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.

Thomas & Betts Corporation

Memphis, Tennessee

www.tnb.com

Thomas & Betts BPLT62BSCR Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual