Thomas & Betts TBM6UCR-LI Installation Manual

Operating Instructions

FOR TBM6UCR-LI

HYDRAULIC COMPRESSION TOOL

Table of Contents

Page

1.0 GENERAL INFORMATION..................... 2

1.1 Safety Rules .........................................2

1.2 Features............................................... 2

1.3 Specifications....................................... 2

2.0 Parts & Accessories .............................. 3

2.1 Hydraulic Compression Tool ................. 3

2.2 Battery. ................................................ 3

2.3 Charger. ............................................... 3

2.4 Carrying Case ...................................... 3

3.0 Operating Instructions .......................... 4

3.1 Charging the Battery............................. 4

3.2 Attaching & Detaching the Battery. ....... 4

3.3 Compression Cycles ............................ 4

3.4 Switch Operations................................ 4

3.5 Compression Operation ....................... 5

3.6 Maintenance & Operation..................... 5

3.7 Trouble Shooting .................................. 6

4.0 Important Operation Precautions ........ 6

4.1 Precautions for the Compression Tool .. 6

4.2 Precautions for the Battery. ..................6

4.3 Precautions for the Charger. ................. 6

5.0 Parts Breakdown................................... 7

5.1 Parts Diagram ...................................... 7

5.2 Parts List.............................................. 8

6.0 Optional Cutting Jaws .......................... 9

6.1 Installing Instructions ............................ 9

TA04716 B Page 1 of 9

IMPORTANT: Read and understand all of the
instructions and safety information in this manual
before operating or servicing this tool.

1.0

1.1

1. BE FAMILIAR WITH YOUR TOOL.
Read the instruction manual. Become aware of its proper
usage as well as the potential hazards.

2. KEEP WORK AREA CLEAN AND WELL LIGHTED.
Poor lighting and cluttered areas invite accidents.

3. USE SAFETY GLASSES.

4. MAINTAIN TOOL WITH CARE.
Keep tool in good condition at all times. Keep it clean for
best and safest performance.

5. DON'T OVER-REACH.
Keep proper footing and balance at all times.

6. NEVER ATTEMPT TO MAKE A COMPRESSION ON A

"HOT" LINE.

Never assume the power is OFF! Determine beforehand if
any electrical hazards could exist when making a
connection to a line or wire.

7. KEEP FINGERS AND OTHER BODY PARTS AWAY

FROM COMPRESSION DIES & MOVING PARTS.

SAFETY RULES

GENERAL INFORMATION

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.

WARNING

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.

FEATURES1.2

• Fully automatic, self-contained power tool.

• Removable battery cartridge - simply change the

cartridge for continuous use.

• One handed operation - control ram advancement
and retraction with one hand.

• Accepts Burndy “W” Dies.

• Fully enclosed weather resistent housing.

• LED work lights.

1.3

SPECIFICATIONS

HYDRAULIC COMPRESSION TOOL:

TBM6UCR-LI

Drive Unit: 1

Dimensions:

Weight:

Capacities:

#8-4/0 kcmil Aluminum

Output:

4.4V DC Motor

22”L x 3.5” W x 4.5”H

8.75 lbs. with battery

#8-300 kcmil CU or

6 Tons

BATTERY:

144-BAT-LI

Battery Type: Sealed Lithium Ion

Voltage:

Dimensions:

Capacities:

Weight:
Charging time:

45 min. 100% Capacity

14.4V DC

4.2”L x 3.3W x 2.6H

3.0Ah

1.2 lbs.
25 min. 80% Capacity

CHARGER:

144-CHR-LI

Input Voltage: 120 - 240 V AC Single Phase

Dimensions:

Weight:

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 notication of any warranted defect, Thomas & Betts will, at its option, repair or replace the defective product. Misuse, misapplication or modication 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.

9”L x 5.7W x 3.2H

3.5 lbs.

TA04716 B Page 2 of 9

2.0

PARTS AND ACCESSORIES

2.1

Jaws

Work Light

HYDRAULIC COMPRESSION TOOL

(TBM6UCR-LI)

LED

LED
Work Light

2.3

2.2

CHARGER (144-CHR-LI

LED Lamp

Power Cord Inlet

BATTERY (144-BAT-LI

)

Contacts

Air Vent

Power Cord

)

Work Light

Button

Release Button

Advance
Trigger

Release

Button

2.4

Contact Cover

Air Vent

Contacts

Air Vent

CARRYING CASE

Hanging
Strap

TA04716 B Page 3 of 9

3.0

OPERATING INSTRUCTIONS

3.1

CHARGING THE BATTERY

1. Connect the power cord to the Charger 144-CHR-LI and to an AC
outlet. The LED Lamp blinks in Red [STAND BY]
NOTE: The rated input voltage for this unit is 100V-240V. Use of
voltages over 260V will result in damage to the charger.

2. Insert the Battery rmly into the charger.
The LED Lamp lights in green [CHARGING].
NOTE: Do not short-circuit the Charger by placing foreign materials
in the contacts on Charger, as this will damage the Charger.

3. Charging takes approximately 25 minutes (80% capacity) and
45 minutes (100% capacity).
When charging is nished, the LED Lamp lights in orange
[COMPLETION].
NOTE: If the LED Lamp displays solid red [HIGH TEMPERATURE],
remove the Battery from the Charger and allow it to cool down
before trying to charge it again.

4. When the battery will no longer charge or hold a charge, the LED
Lamp blinks quickly in red [IMPOSSIBLE TO CHARGE].

5. When the charger is out of order, the LED Lamp does not light up
even if AC power is supplied.

NOTE: Do not power the Charger with a portable generator.

3.2

ATTACHING & DETACHING THE BATTERY PACK

3.3

Battery

LED Lamp

Power Cord

Charger

COMPRESSION CYCLES

1. To attach the Battery, slide it into the base of the Tool
until it stops and the Latches engage.

2. After inserting the Battery, check that it is securely in
place by pulling it gently without pressing the Latches.

3. To detach the Battery, pull out the Battery while pressing
the Latches.

Tool

Battery

This guide indicates the number of compression cycles that
the TBM6UNICR-LI can be expected to perform when the
battery is fully charged. These gures are approximate and will
vary according to the charging and other operating conditions,
such as temperature, humidity, and battery condition.

AVERAGE COMPRESSIONS

CONDUCTOR

PER CHARGE

BAT-144-LI

#6 Cu / Al 250
1/0 Cu /Al 170
4/0 Cu /Al 125

3.4

SWITCH OPERATIONS

1. The jaws close when the Trigger is depressed and stop
when the Trigger is released.

2. To open the jaws, depress the Release Button. The jaws
continue to open while the Release Button is depressed.

Work Light

Button

Trigger

Slide in

Latches
(both sides)

Release

Button

Pull Out

TA04716 B Page 4 of 9

3.5

COMPRESSION OPERATION

1. Open the Jaws fully by pressing the release button (see Step 3.4).

2. Select the appropriate nest for the connector being used (Figure 1).

3. The tool also accepts Burndy “W” type dies. To use Burndy “W” dies,
install over the D Nests and secure in place by the spring loaded pins

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.

WARNING

(Figure 2).

4. Place connector between the nest or dies. Press the trigger and close the jaws (Step 3.4) so the connector is held lightly.
Do not deform the connector.

5. Insert the conductor into the connector.

6. Press the trigger until the compression is complete. A series of clicks will be heard followed by a release in the pressure
when compression is complete.

7. Press the release button (Step 3.4) to open the jaws. The jaws continue to open while the release button is pressed and
will stop when they are fully open.

8. Remove the compressed connector from the tool.

Jaw

O Nest

D Nest

Jaw

Spring
Loaded Pin

“W” Dies

21

Spring

Loaded Pin

FIGURE 1

FIGURE 2

3.6

MAINTENANCE & INSPECTION

1. Very little maintenance is required to ensure that the tool is kept in good working condition.

2. To ensure smooth operation and prevent rust, store the tool in a cool dry area. Ensure that moving parts are lubricated regularly.

3. When the plastic housing becomes dirty, clean it with a soft soaped cloth.

4. Dust, sand, and dirt are a danger for any hydraulic device. After each use, the tool should be wiped with a clean cloth taking care
to remove any residue, especially close to the movable parts.

5. If the tool is maintained regularly, it should provide you with trouble free service.

NOTE: Always remove the battery pack from the unit before replacing parts or maintenance.

TA04716 B Page 5 of 9

3.7

Problem Cause Solution

Charger LED lamp indicates stand by while battery
is inserted.

The charger LED lamp indicates high or low
temperatures.

The motor does not operate at all.

The motor runs but jaws will not close, or jaws
close but will not build pressure.

The jaws will not open

TROUBLE SHOOTING

There is dust or foreign objects lodged at
the battery contacts.

The battery is too hot or cold.

The battery is not charged or defective. Charge or replace the battery.

There is dust or foreign objects lodged at
the battery contacts.

The switch is misaligned.

Insufcient hydraulic oil.

Air in hydraulic system.

Defective hydraulic circuit. Consult tool service 1- 800-284 TOOL (8665).

Tool did not complete a full cycle and
bypass.

The connector is jammed in compression
dies.

The release button is bent or misaligned. Consult tool service 1- 800-284 TOOL (8665).

Remove foreign objects.

Allow the cartridge to reach room temperature
before continuing.

Remove foreign objects.

Check to see if switch is aligned with trigger,
consult tool service 1- 800-284 TOOL (8665).

Consult tool service 1- 800-284 TOOL (8665).

Hold the tool with head towards the oor to
allow air to rise towards top of oil bladder.

Depress trigger and allow tool to reach full
pressure and bypass, then depress release
button to open the jaws.

Depress and hold release button while prying
compression dies apart.

4.0

4.1

PRECAUTIONS FOR COMPRESSION TOOL

1. S

elect the approproiate nest or dies for the connector and
conductor to be compressed. Incorrect combinations
result in inferior connections of the conductors.

2. Never operate the tool without dies installed.

3. Always point the tool away from other people.

4. If the tool is stored for an extended period at a
temperature of less than 25º F (-5º C), the tool should be
allowed to return to room temperature to ensure smooth
operation. Use the tool only after it has been at room
temperature for 1 hour.

5. Do not drop the tool. Dropping the tool may damage the
hydraulic circuit and cause malfunctions.

6.

Keep the head and jaws clean and free of debris. Solvents
can be used to clean the head but should not be used on

IMPORTANT OPERATING PRECAUTIONS

4.2

PRECAUTIONS FOR THE BATTERY PACK

1. Do not short circuit the contacts or expose the battery to
water, oil or solvents.

2. Do not disassemble or attempt to repair the battery or
dispose of in a re.

3. Do not drop or otherwise abuse the battery.

4. Do not leave the battery in locations where it will be
exposed to a temperature greater than 104 degrees F
(40 degrees C) for an extended period.

5. The battery has a limited life. When the crimping
capacity becomes about 1/2 that of the original capacity,
the battery should be replaced.

6. If the battery is stored without being charged, natural
drainage will cause the power to be reduced. The battery
should be charged every 3 months if not in use regularly.

the plastic body. Use soap & water to clean the body.

4.3

PRECAUTIONS FOR THE CHARGER

1. The LED lamp lights up green and remains lit when the unit starts charging a battery. The indicator turns orange when
charging is completed.

2. This unit is for charging battery 144-BAT-LI only. Do not use the charger for any other devices.

3. Allow battery cartridges to cool before charging. Allow at least 15 minutes between charges when charging several batteries
in succession.

4. Charge batteries at an ambient temperature of 50-95 degrees F (10-35 degrees C). Charging time is approximately 25
minutes for 80% capacity and 45 minutes for 100% capacity.

5. Never short circuit the output contacts.

6. Do not expose the charger to water, oil or solvents.

7. Do not disassemble, modify, drop or otherwise abuse the charger.

TA04716 B Page 6 of 9

5.0

PARTS BREAKDOWN

5.1

TBM6UCR-LI PARTS DIAGRAM

TA04716 B Page 7 of 9

5.2

TBM6UCR-LI PARTS LIST

NO. DESCRIPTION CODE QTY NO. DESCRIPTION CODE QTY

1 Housing (L) 1 49 Ram SLND-16 1
2 Housing (R) 1 50 Ram Spring (443) SLND-17 1
3 Switch Unit SLND-04
4 Switch Rod 1 52 Stopper Screw SLND-19 1

SLND-05

1 51 Cover SLND-18 1

5 Switch Knob SLND-06 1 53 Stopper Collar SLND-20 1
6 Spring (187) 40U-10 1 54 Body Head SLND-21 1
7 Release Lever SLND-07 1 55 Slide Pin SLND-22 1
8 Lever Support SLND-08 2 56

M4 X 6 Nylock Screw (D.P.)

R5PD-02 1

9 Spring (701) SLND-09 1 57 Stopper Pin 130D-09 1
10 Led Switch Rubber SLND-10 1 58 Spring (140) 55A-04 1
11 Strap 558-07 1 59 Roller Head SLND-23 1
12 M4 X 10 Screw ROB-159 8 60 Roller SLND-24 2
13 M4 Lock Washer EZ-37
14 M4 Flat Washer 8

EZ-36
15 Power Unit SLND-11
16 S-32 O-Ring 1

EZ-10

8

1

17 Plug SLND-12 1
18 Oil Reservoir SLND-13 1
19 S-36 O-Ring EZ-12 1
20 Bush R14A-19 1
21 Spring (552) EZ-16 2
22 PS-6 Pent Seal EZ-14 2
23 P-6 Back-Up Ring UC-28 2
24 Cylinder Insert EZ-13 2
25 Pump Piston EZ-15 2
26 1/8” Ball 40-20 1
27 M4 X 4 Screw (F.P.) 85-47 1
28 Retainer SLND-14 1
29 M3 X 4 Scew (F.P.) RCP-35 1
30 Spring (5688) EZ-22 2
31 5/32” Ball 22-21 3
32 P-3 O-Ring (U801) EZ-21 2
33 Suction Valve EZ-20 2
34 Filter Screen R14A-22 2
35 SI-12.7 Ring R14A-23 2
36 Spring (689) EZ-23 1
37 P-3 O-Ring (U801) 16-36 2
38 P-3 Back-Up Ring 9H-38 1
39 Release Plug EZ-24 1
40 Release Valve Stem EZ-17 1
41 P-5 O-Ring 5N-35 1
42 Valve Cartridge EZ-25A 1
43 Body SLND-15 1
44 Valve Screw EZ-27 2
45 Spring (686) EZ-26 2
46 3/16” Ball 16-49 2
47 P-28 O-Ring EZ-29 1

P-28 Back-Up Ring (B.C.)

48

55D-03 1

© 2014 Thomas & Betts. All Rights Reserved.

Thomas & Betts Corporation

Memphis, Tennessee

www.tnb.com

TA04716 A Page 8 of 9

6.0

OPTIONAL CUTTING JAWS

6.1

6UNICR-CHCU/AL

Cu — 500 MCM

Al — 1” O.D.

INSTALLING INSTRUCTIONS

6UNICR-CHASCR

ACSR — 336 MCM
Cu /Al — 350 MCM

WARNING

PINCH POINT HAZARD. CUTTING JAWS AT HIGH
FORCE CAN CAUSE SEVERE PERSONAL INJURY.
KEEP ALL BODY PARTS AWAY FROM MOVING
PARTS OF THE TOOL DURING OPERATION.

WARNING

RISK OF SHOCK,

DISCONNECT POWER

BEFORE INSTALLATION.

Body
Head

Cutting
Jaw

Position Cutting
Jaw & Slide into
Body Head

CAUTION

WEAR SAFETY GOGGLES WHEN USING
TOOL WITH CUTTING JAWS.

ATTACHING THE CUTTING JAW:

The above Cutting Jaws are for use on

TBM6UCR-LI and TBM6UNICR-LI Hydraulic

Compression Tools ONLY!

1. Retract the Ram by pressing on the Release Button on the
hydraulic tool (see Figure 3).

2. Pull the Slide Pin out disengaging the Compression Jaw
from the tool Body Head. NOTE: Slide Pin stays
permanently attached to Body Head.

3. Remove Compression Jaw and position the Cutting Jaw in
line with Body Head (see Figure 3).

4. Slide Cutting Jaw into the Body Head (see Figure 3 & 4).

5. Once Cutting Jaw is aligned with the Slide Pin, push the
Slide Pin in locking the Cutting Jaw with the Body Head
(see Figure 4).

6. The hydraulic tool is ready for operation.

For Part or Service, contact the Tool Service Center at

1- 800-284 TOOL (8665).

Slide Pin

(Pull Out)

Release
Button

Figure 3

Cutting
Jaw

Slide Pin

(Push In)

Release
Button

Figure 4

TA04716 B Page 9 of 9