ABB Thomas & Betts Blackburn TBM62CR-LI User manual

Operating Instructions
FOR TBM62CR-LI
HYDRAULIC COMPRESSION TOOL
TA04713 A Page 1 of 8
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
Table of Contents

IMPORTANT: Read and understand all of the
instructions and safety information in this manual
before operating or servicing this tool.
1.0 GENERAL INFORMATION
SAFETY RULES
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.
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.
•Accepts Burndy “W” Dies.
•Fully enclosed weather resistent housing.
•LED work lights.
SPECIFICATIONS
HYDRAULIC COMPRESSION TOOL:
TBM62CR-LI
Drive Unit: 1 4.4V DC Motor
Dimensions: 18”L x 3.5” W x 4.5” H
Weight: 8.75 lbs. with battery
Capacities: #8-600 kcmil CU or
#8-400 kcmil Aluminum
Jaw Opening: 1.8”
Output: 6 Tons
BATTERY:
144-BAT-LI
Battery Type: Sealed Lithium Ion
Voltage:
14.4V DC
Dimensions: 4.2”L x 3.3W x 2.6H
Capacities: 3.0Ah
Weight: 1.2 lbs.
Charging time: 25 min. 80% Capacity
45 min. 100% Capacity
CHARGER:
144-CHR-LI
Input Voltage: 120 - 240 V AC Single Phase
Dimensions:
9”L x 5.7W x 3.2H
Weight: 3.5 lbs.
1.3
TA04713 A Page 2 of 8
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. Misuse, misapplication or modification 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.

TA04713 A Page 3 of 8
HYDRAULIC COMPRESSION TOOL
2.1
(TBM62CR-LI)
Ram
LED
Work Light
LED
Work Light
Work Light
Button
Hanging
Strap
Advance
Trigger
Release Button
Air Vent
Contact Cover
Air Vent
Release
Button
Contacts
BATTERY
(
144-BAT-LI
)
2.2
CHARGER
(
144-CHR-LI
)
2.3
LED Lamp Contacts
Air Vent
Power Cord Inlet Power Cord
CARRYING CASE
2.4
2.0 PARTS AND ACCESSORIES

TA04713 A Page 4 of 8
CHARGING THE BATTERY
3.1
LED Lamp
Battery
Power Cord
Charger
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 firmly 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 finished, 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.
ATTACHING & DETACHING THE BATTERY PACK
3.2
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
Slide in Pull Out
Battery
Latches
(both sides)
COMPRESSION CYCLES
3.3
This guide indicates the number of compression cycles that
the TBM62CR-LI can be expected to perform when the
battery is fully charged. These figures are approximate and will
vary according to the charging and other operating conditions,
such as temperature, humidity, and battery condition.
CONDUCTOR
AVERAGE COMPRESSIONS
PER CHARGE
BAT-144-LI
#6 Cu / Al 250
1/0 Cu /Al 170
4/0 Cu /Al 125
3.0 OPERATING INSTRUCTIONS
SWITCH OPERATIONS
3.4
1. The ram advances when the Trigger is depressed and
stops when the Trigger is released.
2. To retract the ram, depress the Release Button. The ram
continues to retract while the Release Button is
depressed.
Trigger
Release
Button
Work Light
Button

TA04713 A Page 5 of 8
COMPRESSION OPERATION
3.5
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.
FIGURE 2
FIGURE 3
To close, lift the C-Head
until it is securely engages to
the Latch .
Spring
Loaded Pin
“W” Dies
1
2
FIGURE 4
Latch Engaged
1. Retract the Ram fully by pressing the release button (see Step 3.4).
2. Open the tool head by lifting the Latch (Figure 1).
3.
Select the appropriate size dies for the connector being used.
4. Loosen the two Die Retaining Screws. Insert one die half into the C-head
and then insert the other half of the die into the Ram (Figure 2). Tighten the Die Retaining Screws.
5.
The tool also accepts Burndy “W” type dies. Use of Burndy “W” dies require that the die set DBL be installed first according to
step 4. The “W” dies are then installed over the DBL dies and are secured in place by the spring loaded pins (Figure 3).
6. Close by lifting the C-Head until it is securely engaged to the Latch (Figure 4).
7. Place connector between the dies. Press the trigger and advance the Ram (Step 3.4) so the connector is held lightly
between the dies. Do not deform the connector.
8. Insert the conductor into the connector.
9. 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.
10. Press the release button (Step 3.4) to retract the ram. The ram continues to retract while the release button is pressed.
The ram stops when it is fully retracted.
11. Remove the compressed connector from the tool.
FIGURE 1
Lift Latch
Die Retaining
Screw
Die Retaining
Screw
C-Head Ram
2
1
DBL Dies
or
6 Ton Series Dies
MAINTENANCE & INSPECTION
3.6
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.

TA04713 A Page 6 of 8
4.0 IMPORTANT OPERATING PRECAUTIONS
TROUBLE SHOOTING
3.7
Problem Cause Solution
Charger LED lamp indicates stand by while battery
is inserted.
There is dust or foreign objects lodged at
the battery contacts. Remove foreign objects.
The charger LED lamp indicates high or low
temperatures. The battery is too hot or cold. Allow the cartridge to reach room temperature
before continuing.
The motor does not operate at all.
The battery is not charged or defective. Charge or replace the battery.
There is dust or foreign objects lodged at
the battery contacts. Remove foreign objects.
The switch is misaligned. Check to see if switch is aligned with trigger,
consult tool service.
The motor runs but ram will not advance, or ram
advances but will not build pressure.
Consult tool service.
Air in hydraulic system.
Insufficient hydraulic oil.
Hold the tool with head towards the floor to
allow air to rise towards top of oil bladder.
Defective hydraulic circuit. Consult tool service.
The ram will not retract
Tool did not complete a full cycle and
bypass.
Depress trigger and allow tool to reach full
pressure and bypass, then depress release
button to retract the ram.
The connector is jammed in compression
dies.
Depress and hold release button while prying
compression dies apart.
The release button is bent or misaligned. Consult tool service.
4.1 PRECAUTIONS FOR COMPRESSION TOOL
1. Select the approproiate 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 ram clean and free of debris. Solvents
can be used to clean the head but should not be used on
the plastic body. Use soap & water to clean the body.
PRECAUTIONS FOR THE BATTERY PACK
4.2
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 fire.
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 cutting 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.
PRECAUTIONS FOR THE CHARGER
4.3
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.

TBM62CR-LI PARTS DIAGRAM
5.1
5.0 PARTS BREAKDOWN
TA04713 A Page 7 of 8

TA04713 A Page 8 of 8
TBM62CR-LI PARTS LIST
5.2
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
© 2013 Thomas & Betts. All Rights Reserved.
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
SLND-05
1 53 Stopper Collar SLND-20 1
4 Switch Rod 1
5 Switch Knob SLND-06 1
6 Spring (187) 40U-10 1
7 Release Lever SLND-07 1
8 Lever Support SLND-08 2
9 Spring (701) SLND-09 1
10 Led Switch Rubber SLND-10 1
11 Strap 558-07 1
12 M4 X 10 Screw ROB-159 8
13 M4 Lock Washer EZ-37
EZ-36
8
14 M4 Flat Washer 8
15 Power Unit SLND-11
EZ-10
1
16 S-32 O-Ring 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
48
P-28 Back-Up Ring (B.C.) 55D-03 1