Page 1
TBM6 and TBM6S
Compression Tool Instructions
Read and understand all of the instructions
and safety information in this manual before
operating or servicing this tool.
Table of Contents
1.0 Operating Instructions . . . . . . . . . . . . . . . . . . . 2
1.1 Tool Description . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Die Description . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Choosing The Die Nest (Sta-Kon®) . . . . . . . . . . . . . . . 2
1.4 Choosing The Die Nest (Color-Keyed®) . . . . . . . . . . . . . 2
1.5 Removing, Installing, and Changing Dies . . . . . . . . . . . . 3
1.6 Preparing the Conductor . . . . . . . . . . . . . . . . . . 3
1.7 Making a Compression . . . . . . . . . . . . . . . . . . . 3
2.0 Installation Test Procedure . . . . . . . . . . . . . . . . . 4
2.1 Installation Test Procedure . . . . . . . . . . . . . . . . . . 4
2.2 Tensile Test Procedure . . . . . . . . . . . . . . . . . . . 4
3.0 Calibration Verification . . . . . . . . . . . . . . . . . . . 5
3.1 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Handle Spread Check . . . . . . . . . . . . . . . . . . . . 5
3.3 Gaging Procedure . . . . . . . . . . . . . . . . . . . . . 5
3.4 Color-Keyed® Gaging Table . . . . . . . . . . . . . . . . . 6
3.5 Sta-Kon® Gaging Table . . . . . . . . . . . . . . . . . . . 6
TA01977 E Page 1 of 6
Page 2
1.0
OPERATING INSTRUCTIONS
WARNING
Tools are NOT insulated for use on or near energized conductors. Use
of these tools near energized conductors may lead to electrical shock,
causing severe injury or death. DO NOT use these tools near energized
conductors without adequately insulating operator and surroundings.
Pinch point hazard. Compression Dies at high force can cause severe
personal injury. Keep all body parts away from moving parts of the tool
during operation.
1.1 1.2
RAM
TOOL HEAD
TOOL DESCRIPTION DIE DESCRIPTION
ADJUSTING SCREW
LOCKSCREW
SHURE STAKE
MECHANISM
®
HANDLES
GRIPS
(TBM6S ONLY)
SHURE STAKE® MECHANISM IS DESIGNED
TO PROVIDE COMPLETE CLOSURE.
The TBM6S compression tool is equipped with the Shure Stake® full stroke
compelling mechanism. If it becomes necessary to release the Shure Stake®
Mechanism before completion of the crimp cycle, disengage ratchet as fol-
lows. Slightly squeeze handles, and push the dowel pin, releasing the locking
COLOR-KEYED® DIES STA-KON® DIES
LOCKING
PIN NOTCH
NEST
WARNING
SHURE STAKE® SAFETY RELEASE
mechanism allowing the handles to open.
DIE LOCATOR PIN
RIB
NEST
INDENTOR
INDENTOR LOCKING
PIN NOTCH
DIE LOCATOR PIN
INDENTOR
BLOCK
RIB
1.3
CAUTION
Any other combination may result in a connection which does not meet established standards.
CHOOSING THE DIE NEST (STA-KON®)
DESCRIPTION SIZE TYPE
NON-INSULATED
TERMINALS
&
SPLICES
INSULATED
TERMINALS
&
SPLICES
Use only a listed (UL and/or CSA) Thomas & Betts connector with this tool.
DIE CAT. NO.
NEST
11803
11805
11806
11807
11808
11809
11810
11811
INDENTOR
(LOWER)
11822 (SET)
11823 (SET)
11824 (SET)
11802
TUBULAR
D
BRAZED
TUBULAR
E
BRAZED
TUBULAR
F
BRAZED
TUBULAR
G
TUBULAR
H
TUBULAR
J
TUBULAR
K
TUBULAR
L
TUBULAR
M
TUBULAR 11821 (SET)
RD
BRAZED
TUBULAR
RE
BRAZED
TUBULAR
RF
BRAZED
RG TUBULAR
RH TUBULAR 11825 (SET)
RJ TUBULAR 11826 (SET)
RK TUBULAR 11827 (SET)
RL TUBULAR 11828 (SET)
RM TUBULAR 11829 (SET)
(UPPER)
1.4
CHOOSING THE DIE NEST (COLOR-KEYED
Match color on
connector to the
color on the die.
Reference chart.
NOTE: A crimping
nest with more
than one color
band may be
used to crimp
Color-Keyed
®
connectors
matching any of
the nest color
bands.
COLOR-KEYED
“H” TAP
CAT. NO.
63105 13474 13477 ORANGE
63110 13470 13470 GREEN
63118 13470 13470 GREEN
63125 13470 13470 GREEN
63140 13471 13471 BLUE
UPPER
DIE
13478
(1 NEST)
13472
(2 NEST)
13474
(4 NEST)
13475
(4 NEST)
13479
(1 NEST)
UPPER DIE
CAT. NO.
COLOR-KEYED
CONNECTORS
UPPER DIE
NEST
COLORS
BROWN 87 13478
BLUE & RED
GRAY
GREEN
BLACK & GOLD
BROWN
ORANGE & TAN
RED
BLUE
PINK
PURPLE & OLIVE
BLACK 80 13476
®
“H” TAPS
LOWER DIE
CAT. NO.
DIE
CODE
24 & 21
29
37
45
33
50
71
76
42
54
®
USED WITH
LOWER DIE
CAT. NO.
13476
13477
13477
COLOR
CODE
®
)
TA01977 E Page 2 of 6
Page 3
1.5
ALUMA
SHIELD
REMOVING, INSTALLING, AND CHANGING DIES
REMOVING DIES
Open handles of tool until fully extended. Pull locking pin all the
way down, disengaging it from the lower die. Slip the die along
the groove until out of tool. Pull upper die out from under the die
retaining spring thus removing it from the tool.
INSTALLING OR CHANGING DIES
Hold tool with die retaining spring facing you and open handles of
tool until they are fully extended. Insert the upper die first. Hold the
upper die with the desired crimping nest facing toward ram. Insert
the upper die under the die retaining spring in the tool head. The
die retaining spring will hold the die by pressure on the die locator
pin.
Hold the lower die with the rib down and the locking pin notch to
the right. Slip rib of lower die into groove in ram. Push the lower die
into ram until the die is properly seated and the locking pin snaps
into the notch.
UPPER DIE
DIE RETAINING
SPRING
LOWER DIE
RAM
LOCKING PIN
1.6
PREPARING CONDUCTOR
1. Strip insulation properly without cutting or nicking the conductor
strands. Refer to the instruction sheet supplied with the connectors to
determine strip length.
2. For aluminum cable, smear a thin layer of joint compound onto the
conductor strands and brush it in between the strands with a wire brush
or emery cloth.
1.7
MAKING A COMPRESSION
1. Insert prepared conductor into connector.
2. Color-Keyed
®
- Locate connector in die grooves
of the tool so the die is between the color code
marks for copper and on the color code marks for
aluminum, see Steps 1, 2 and 3.
®
Sta-Kon
- Locate terminal in die grooves of the
tool so the die is centrally located over barrel of the
terminal.
NOTE: Some Color Keyed
®
connectors require
more than one compression. If more than one
compression is indicated, the first compression
should be in the indicated area nearest to the tongue
of the terminal and nearest the center of a splice,
and then working progressively toward the end of the
STEP 2
barrel.
3. Refer to the instruction sheet supplied with the
connectors to determine the number of required
compressions.
4. Close handles of tool completely for each
compression.
TYPICAL COPPER
INSTALLATION
CABLE
DIE
DIE
TYPICAL ALUMINUM
INSTALLATION
CABLE
DIE
DIE
STEP 1
STEP 3
TA01977 E Page 3 of 6
Page 4
2.0
INSTALLATION TEST PROCEDURE (TBM6S ONLY)
WARNING
SHURE STAKE® SAFETY RELEASE
becomes necessary to release the Shure Stake® Mechanism before completion of the crimp cycle, disengage ratchet as follows. Slightly squeeze
handles, and push the dowel pin, releasing the locking mechanism allowing the handles to open.
The TBM6S compression tool is equipped with the Shure Stake® full stroke compelling mechanism. If it
2.1
INSTALLATION TEST PROCEDURE
Using a tool that has passed the calibration requirements install a
minimum of six (6) terminals for each die nest on the appropriate
wire for which a performance check is required. In order to obtain
valid and consistent results, perform installation procedure as
follows:
1. Strip conductor approximately 1/4” longer than the connector barrel.
(Strip length for test purposes only. For actual installation, refer to
the instruction sheet supplied with the connectors.)
CAUTION
Care should be taken to strip the insulation of the conductor
without cutting or nicking the conductor strands, as this
condition will result in premature pull-test failures.
2. For aluminum conductor, smear a thin layer of joint compound onto
the cable and brush it in
emery cloth.
3. Insert stripped conductor into connector barrel until it bottoms
out.
4. Choose an installing die with the same color marking as the
connector.
5.
Color-Keyed
®
- Locate connector in die grooves of tool, so that die
is between the color code marks for copper and on the color code
between the strands with a wire brush or
marks for aluminium, see graphics below.
Sta-Kon
®
- Locate
terminal in die grooves of the tool so the die is centrally located
over barrel of the terminal.
NOTE: Some Color Keyed® connectors require more than one
compression. If more than one compression is indicated, the
first compression should be in the indicated area nearest to
the tongue of the terminal and nearest the center of a splice,
and then working progressively toward the end of the barrel.
6. Refer to the instruction sheet supplied with the connectors to
determine the number of required compressions.
7. Squeeze handles fully closed until SHURE STAKE® mechanism
releases.
TYPICAL COPPER
INSTALLATION
COLOR CODE
BANDS
CABLE
INTERCHANGEABLE
NEST
CONNECTOR
FIXED
NEST
TYPICAL ALUMINUM
INSTALLATION
INTERCHANGEABLE
COLOR CODE
BANDS
CABLE
NEST
CONNECTOR
FIXED
NEST
2.2
TENSILE TEST PROCEDURE
1. Install test sample in a tension-testing machine or a suitable pull-test
fixture.
NOTE: The pull is to be exerted gradually. An abrupt pull is not a proper test method.
2. Subject each sample to an axial pull which is to be increased until failure of the
connection occurs. See graphics below.
3. The pull force required to separate a terminal from its associated wire shall be no less
than the minimum pullout (see table on the right).
NOTE: On “C” tap and wire joints, only the smallest wire in each combination is to be
tested for pullout.
EXAMPLES OF TENSILE TESTING MACHINES
1. Ametek Testing Equipment Systems, E. Moline, IL 61244. Mechanical Force Gage Model
No. D-150M, Testing Stand Model No. CTM.
2. John Chatillion & Sons, Kew Gardens, N.Y., N.Y. 11415. Gage Model No. DPPH-100 or
DPPH-200, Testing Stand Model No. HTC.
TERMINAL
FORCE
TYPICAL COPPER TEST SAMPLE
WIRE
TERMINAL
FORCE FORCE
TYPICAL ALUMINUM TEST SAMPLE
CABLE
SIZE
12 70 35
10 80 40
8 90 45
6 100 50
4 140 70
2 180 90
1 200 100
1/0 250 125
2/0 300 150
3/0 350 175
4/0 450 225
250 500 250
300 550 275
350 600 300
400 650 325
500 800 400
*Conforms to UL and CSA requirements
WIRETERMINAL
MIN. PULL-OUT (lbs.*)
COPPER ALUMINUM
TERMINAL
FORCE
TA01977 E Page 4 of 6
Page 5
3.0
CALIBRATION VERIFICATION
NOTE: Calibration verification of the tool is mandatory when switching between 13400 Color-Keyed
Otherwise, it should be performed whenever damage or suspected damage has occurred or as often as operating conditions warrant.
3.1
1. 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.
3.2
To ensure the tool will produce a reliable compression, the tool must be properly adjusted.
Tool adjustment is mandatory when switching between 13400 Color-Keyed® and 11800 series Sta-Kon® dies.
CHECKING TOOL ADJUSTMENT
1. Insert upper and lower dies in place.
2. Lay tool on a flat surface, open handle A and allow
it to close under its own weight. The dies should be
touching.
3. Measure distance between handle grips. In a properly
adjusted tool, the distance should be betwen 11” and
14”. If it is less than 11” or more than 14”, the tool
needs adjustment. (See graphic below).
VISUAL INSPECTION
HANDLE SPREAD CHECK
ADJUSTING TOOL
1. Loosen lockscrew.
2. To increase distance between handles, turn adjusting
screw clockwise.
3. To decrease distance between handles, turn
adjusting screw counterclockwise.
4. Tighten lockscrew.
5. Recheck handle distance. Adjust again, if necessary.
®
and 11800 Sta-Kon® series dies.
LOCKING PIN
LOWER DIE
UPPER DIE
DIE RETAINING SPRING
TOOL HEAD RAM
3.3
GAGING PROCEDURE
NOTE: Wipe dies before gaging.
1. Squeeze handles until jaws are fully closed.
2. Select gage pin which can be inserted into nest
with minimal hand pressure, see graphic below.
3. Gage pin should fall between the limits shown on
tables in section 3.4 & 3.5.
ADJUSTING SCREW
LOCK SCREW
STOP
HANDLE
FLAT SURFACE OR TABLE TOP
GAGE PIN
A
MEASURE HERE
TA01977 E Page 5 of 6
Page 6
3.4
COLOR-KEYED® GAGING
3.5
STA-KON® GAGING
CONNECTORS AND “H”-TAPS
13400 SERIES DIES
DIE
CODE
COLOR
21 RED 13475 13477 .168 - .177
24 BLUE 13475 13477 .181 - .201
29 GRAY 13472 13476 .264 - .276
33 BROWN 13474 13477 .307 - .321
37 GREEN 13474 13477 .345 - .359
42 PINK 13475 13477 .383 - .398
45 BLACK 13474 13477 .408 - .423
50 ORANGE 13474 13477 .469 - .487
54 PURPLE 13475 13477 .524 - .539
62 YELLOW 13473 13476 .555 - .575
45 GOLD 13474 13477 .408 - .423
50 TAN 13474 13477 .469 - .487
54 OLIVE 13475 13477 .524 - .539
60 RUBY 13473 13476 .555 - .575
66 WHITE 13473 13476 .622 - .637
71 RED 13472 13476 .704 - .720
76 BLUE 13472 13476 .704 - .720
80 BLACK 13479 13476 .775 - .790
87 BROWN 13478 13478 .865 - .885
O GREEN 13470 13470 .808 - .832
D BLUE 13471 13471 1.178 - 1.202
GROOVE
CAT. NO.
UPPER DIE
CAT. NO.
LOWER DIE
GAGING
MIN. - MAX.
NOTE: If tool can not be calibrated, do not
attempt repair or adjustment. Call nearest T&B
tool service center to arrange for repair service.
Any change, modification or alteration of the
tool or use by the customer in a manner other
than as specified by T&B shall void all warranties
express or implied and the customer shall,
therefore, assume all liability for any damage
or injury caused by said changed, modified
or altered tool or improper usage of such tool.
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 notification 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 modification 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.
TERM
SIZE
TERM
TYPE
TUBULAR AIRCRAFT
D
TUBULAR CODE
BRAZED CODE
TUBULAR AIRCRAFT
E
TUBULAR CODE
BRAZED CODE
TUBULAR AIRCRAFT
F
TUBULAR CODE
BRAZED CODE
G TUBULAR
H TUBULAR
J TUBULAR
K TUBULAR
L TUBULAR
M TUBULAR
TUBULAR AIRCRAFT
RD
TUBULAR CODE
BRAZED CODE
TUBULAR AIRCRAFT
RE
TUBULAR CODE
BRAZED CODE
TUBULAR AIRCRAFT
RF
TUBULAR CODE
BRAZED CODE
RG TUBULAR
RH TUBULAR
RJ TUBULAR
RK TUBULAR
RL TUBULAR
RM TUBULAR
TERMINALS AND SPLICES
11800 SERIES DIES
DIE CAT. NO.
WIRE
TYPE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
AIRCRAFT
CODE
NEST
(STATIONARY)
11803
11805 .167
11806 .206
11807 .234
11808 .272
11809 .250
11810 .266
11811 .312
INDEN-
TOR
(MOVEABLE)
11802
11821 (SET) .170
11822 (SET) .202
11823 (SET) .254
11824 (SET) .321
11825 (SET) .339
11826 (SET) .370
11827 (SET) .382
11828 (SET) .456
11829 (SET) .554
GAGING
±.010
.152
CONTACT THOMAS & BETTS TOOL SERVICE CENTER AT 1-800-284-TOOL (8665)
© 2016 Thomas & Betts Corporation.
All Rights Reserved.
FOR PARTS OR SERVICE,
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
TA01977 E Page 6 of 6
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