TBM8 and TBM8S
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 Applications . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Choosing the Die Nest . . . . . . . . . . . . . . . . . . . 2
1.4 Removing and Installing Die . . . . . . . . . . . . . . . . . 2
1.5 Preparing the Conductor . . . . . . . . . . . . . . . . . . 3
1.6 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 Verifi cation . . . . . . . . . . . . . . . . . . . 5
3.1 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Handle Spread Check . . . . . . . . . . . . . . . . . . . . 5
3.3 Gaging Procedure . . . . . . . . . . . . . . . . . . . . . 5
3.4 Gaging Table . . . . . . . . . . . . . . . . . . . . . . . 6
TA01978 C Page 1 of 6
1.0
OPERATING INSTRUCTIONS
WARNING
Keep fi ngers clear of die nests whenever handles are brought together.
WARNING
The TBM8S 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 follows. Slightly squeeze handles, and push the dowel
pin, releasing the locking mechanism allowing the handles to open.
SHURE STAKE® SAFETY RELEASE
1.1
TOOL HEAD
DIE
SLOT
RAM
SHURE STAKE® MECHANISM IS DESIGNED
1.3
TOOL DESCRIPTION
SHURE STAKE
MECHANISM
(TBM8S ONLY)
LOCKSCREW
DOWEL PIN
ADJUSTING SCREW
TO PROVIDE COMPLETE CLOSURE.
®
CHOOSING THE DIE NEST
Match color on connector to the color on the die.
Reference chart below.
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.
DIE CAT. NO.
13461
13462
13463
13464
13465 White-66 66
13466 Red-71 71
13467 Blue-76 76
13468 Brown-87 87
DIE GROOVE
COLOR
Red 21
Blue 24
Grey 29
Brown 33
Green 37
Pink 42
Black 45
Orange 50
Purple 54
Yellow 62
Gold 45
Tan 50
Olive 54
Ruby 60
EQUIV. HEX
DIE CODE NO.
HANDLES
GRIPS
®
NEST
BLK
PINK
ORNG
COLOR CODE
GREEN
1.2
APPLICATIONS
1. This tool is suitable for installing Color-Keyed
lugs and splices, #8 to 500 MCM copper and #10
to 350 MCM aluminum.
2. This tool is also suitable for installing C-Taps from
catalog number 54705 to 54750.
3. Check label and connector for UL and/or CSA
monogram and letters AL or AL9CU. Connectors
marked AL are listed for use on aluminum
conductors only. Connectors marked AL9CU
are listed for aluminum and copper conductors.
Use only a listed Thomas & Betts connector with
this tool. Any other combination may result in
a connection which does not meet established
standards.
1.4
REMOVING & INSTALLING DIE
REMOVING DIE
Open handles of tool until fully extended. Loosen
die locking screw, disengaging it from the die.
Pull die out from the tool.
INSTALLING OR CHANGING DIE
Hold tool with die locking screw facing you and
open handles of tool until they are fully extended.
Hold the die with the desired crimping nest and
color code in lower right corner. Tighten the die
locking screw in the tool head.
DIE LOCKING SCREW
BLK
PINK
GREEN
ORNG
DIE
CAUTION
Use only a listed (UL and/or CSA) Thomas & Betts connector with this tool.
Any other combination may result in a connection which does not meet established standards.
TA01978 C Page 2 of 6
1.5
1. Strip insulation properly without cutting or nicking
the conductor strands. Refer to the instruction sheet
supplied with the connectors regarding strip length.
2. For aluminum conductor, smear a thin layer of joint
compound onto the cable and brush it in with a wire
brush or emery cloth.
PREPARING THE CONDUCTOR
SHIELD
ALUMA
1.6
1. Insert prepared conductor into connector.
2. Locate connector in die grooves of tool, so the die is between the color code marks for copper and on the color
code marks for aluminium, see graphics below.
3. Some connectors require more than one compression. Refer to the instruction sheet supplied with the connectors
regarding the number of compressions required. If more than one compression is indicated, the fi rst compression
should be in the indicated area nearest to the tongue of a terminal and nearest the center of a splice, and then
working progressively toward the end of the barrel.
4. Close handles of tool completely for each compression.
MAKING A COMPRESSION
STEP 1
TYPICAL COPPER
INSTALLATION
CABLE
DIE
DIE
TYPICAL ALUMINUM
INSTALLATION
CABLE
DIE
DIE
STEP 2 STEP 3
TA01978 C Page 3 of 6
2.0
INSTALLATION TEST PROCEDURE (TBM8S ONLY)
WARNING
SHURE STAKE® SAFETY RELEASE
becomes necessary to release the Shure Stake
handles, and push the dowel pin, releasing the locking mechanism allowing the handles to open.
The TBM8S compression tool is equipped with the Shure Stake® full stroke compelling mechanism. If it
®
Mechanism before completion of the crimp cycle, disengage ratchet as follows. Slightly squeeze
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:
Strip conductor approximately 1/4” longer than the connector
1.
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 with a wire brush or 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. Locate connector in die grooves of tool, so that die is between
the color code marks for copper and on the color code marks for
aluminium, see graphics below.
®
6. Some Color Keyed
connectors require more than one
compression. Refer to the instruction sheet supplied with
the connectors regarding the number of compressions
required. If more than one compression is indicated, the fi rst
compression should be in the indicated area nearest to the
tongue of a terminal and nearest the center of a splice, and
then working progressively toward the end of the barrel.
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
fi xture.
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.
FORCE
TERMINAL
WIRE
TERMINAL
TYPICAL COPPER TEST SAMPLE
FORCE
TERMINAL
TYPICAL ALUMINUM TEST SAMPLE
CABLE
SIZE
12 70 35
10 80 40
890 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
WIRE
MIN. PULL-OUT (lbs.*)
COPPER ALUMINUM
TERMINAL
FORCE
TA01978 C Page 4 of 6
3.0
CALIBRATION VERIFICATION
NOTE: Calibration verifi cation of the tool should be performed whenever damage or suspected damage has occurred or as
often as operating conditions warrant.
3.1
VISUAL INSPECTION
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.
3.3
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.
GAGE PIN
3.2
HANDLE SPREAD CHECK
To ensure the tool will produce a reliable
compression, the tool must be properly adjusted.
CHECKING TOOL ADJUSTMENT
1. Insert die in place.
2. Lay tool on a fl at surface. Open handle A and
allow it to close under its own weight. The ram
should be touching the die.
3. Measure distance between handle grips. In
a properly adjusted tool, the distance should
be between 11” and 14”. If it is less than 11”
or more than 14”, the tool needs adjustment.
(See graphic below).
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 lock screw.
5. Recheck handle distance. Adjust again, if
necessary.
RAM JUST
TOUCHING DIE
DIE
ADJUSTING SCREW
LOCK SCREW
HANDLE
A
MEASURE
HERE
3.4
GAGING TABLE
GROOVE
COLOR
RED
BLUE
GRAY
BROWN
GREEN
PINK
BLACK
ORANGE
PURPLE
YELLOW
GOLD
TAN
OLIVE
RUBY
WHITE 13465 .609-.632
RED 13466 .653-.677
BLUE 13467 .686-.710
BROWN 13468 .855-.883
DIE
CAT. NO.
13461
13462
13463
13464
GAGING
MIN. - MAX.
.165-.181
.181-.210
.230-.251
.260-.281
.313-.335
.351-.371
.383-.406
.429-.454
.480-.503
.529-.562
.383-.406
.429-.454
.480-.503
.533-.553
RETAINING SCREW
FLAT SURFACE OR
TABLE TOP
TA01978 C Page 5 of 6
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
notifi cation 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 modifi cation 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.
FOR PARTS OR SERVICE,
CONTACT THOMAS & BETTS TOOL SERVICE CENTER AT 1-800-284-TOOL (8665)
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
© 2008 Thomas & Betts Corporation.
All Rights Reserved.
TA01978 C Page 6 of 6
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