blackburn TBM6PCR-LI User manual

Operating Instructions
FOR TBM6PCR-LI
HYDRAULIC COMPRESSION TOOL
TA04702 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
Page
3.4 Switch Operations.................................................................. 4
3.5 Compression Operation ......................................................... 5
3.6 Maintenance & Operation....................................................... 5
3.7 Trouble Shooting.................................................................... 5
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 - control ram advancement
and retraction with one hand.
•Protective rubber boot on “C” Head.
•Accepts Burndy “W” Dies.
SPECIFICATIONS
HYDRAULIC COMPRESSION TOOL:
TBM6PCR-LI
Drive Unit: 1 4.4V DC Motor
Dimensions: 13”L x 2.5”W x 12”H
Weight: 8.5 lbs. with battery
Capacities: #8-600 kcmil CU or
#8-400 kcmil Aluminum
Jaw Opening: 0.95”
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
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TA04702 A Page 3 of 8
HYDRAULIC COMPRESSION TOOL
2.1
(TBM6PCR-LI)
RAM
Hanging Strap
LED Indicator
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

TA04702 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 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.
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 inPull Out
Battery
Latches
(both sides)
COMPRESSION CYCLES
3.3
This guide indicates the number of compression cycles that
the TBM6PCR-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.
CONDUCTOR
AVERAGE COMPRESSIONS
PER CHARGE
BAT-144-LI
#6 Cu / Al 300
1/0 Cu /Al 220
4/0 Cu /Al 175
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

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12
COMPRESSION OPERATION
3.5
1. Select the appropriate size dies for the connector being used.
2. Insert one die half into the C-head. Insert the other half of
the die into the Ram (Figure 1).
3.
The tool also accepts Burndy “W” type dies. Use of Burndy “W”
dies require that the die set DBL be installed rst according to
step 2. The “W” dies are then installed over the DBL dies and
are secured in place by the spring loaded pins (Figure 2).
4. 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.
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. The LED indicator (Step
2.1) on either side of the tool will show GREEN when a
complete compression is made. A RED indicator light will
show if the compression is incomplete, due to early release
of the trigger or a low battery. An ORANGE indicator will
show if the battery is getting low, but the compression is still
completed.
7. 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.
8. Remove the compressed connector from the tool.
Ram
C-Head
FIGURE 1
FIGURE 2
DBL Dies
or
6 Ton Series Dies
“W” Dies
Spring Loaded Pin
Spring Loaded
Pin (under boot)
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.
21
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.
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. Charge 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.
Insufcient hydraulic oil.
Hold the tool with head towards the oor 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.

TA04702 A Page 6 of 8
4.0 IMPORTANT OPERATING PRECAUTIONS
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 or refund the purchase price. Proof of purchase is required. Misuse or unauthorized modi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.
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 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.
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.

TBM6PCR-LI PARTS DIAGRAM
5.1
5.0 PARTS BREAKDOWN
TA04702 A Page 7 of 8

TA04702 A Page 8 of 8
TBM6PCR-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 M4 X 20 Screw 558-01 6 49 PS-9 Pent Seal 32-18 1
2 Housing (R) 1 50 P-9 Back-Up Ring (B.C.) 32A-01 1
3 M3 x 6 Screw R150-2
558-03
1 51 Spring (590) R150-23 1
4 Top Cover 1 52 PS-20 Pent Seal R150-24 1
5 Switch Unit 558-04 1 53 P-20 Bck-Up Ring (B.C.) 35-18 1
6 LED Harness 558-05 1 54 Pump Piston (1) 558-15 1
7 Circuit Board 558-06 1 55 P-6 O-Ring RB-70 1
8 Strap 558-07 1 56 Pump Piston (2) 558-16 1
9 M3 X 5 Screw (T.P.) ROB-94 1 57 P-3 O-Ring 16-36 1
10 Retaining Plate 458-01 1 58 Release Vavle Stem ROB-135 1
11 Spring (639) 458-02 1 59 Spring (678) 558-17 1
12 Lever Stopper 558-08 1 60 Spring (66) 85-40 1
13 3 X 16 Parallel Pin 558-09
558-10
1 61 9/32” Ball 16-40 2
14 Switch Knob 1 62 Spring (67) 85-39 2
15 Spring (599) R150-09 1 63 Valve Screw (10) 410-44 2
16 Housing (L) 1 64 P-28 O-Ring 300-21 1
17 Power Unit 558-12 1 65 P-28 Back-Up Ring (B.C.) 55D-03 1
18 M4 X 14 Screw (Ni) ROB-128B 4 66 Ram RC58-01 1
19 Spring (598) R150-13 1 67 M4 X 5 Screw (C.P.) 55A-24 2
20 Push Pin R150-14 1 68 Ram Spring (446) 20-76 1
21 Release Lever 558-13 1 69 Head RC58-02B 1
22 4 X 16 Dowel Pin (G) 24-01 1 70 M5 X 8 Nylock Screw (D.P.) 85F-03 1
23 Reservoir Cap 410-55 1
24 Magnet ROB-25 1
72 Retaining Screw 58-01 4
25 Oil Reservoir (36) R4412-01 1
73 Push Pin 58-02 4
26 G-30 O-Ring 75-26 1
74 Spring (5) 58-03 2
27 M3 X 16 Screw R150-16 2
75 Collar 58-04 2
28 Valve Block R150-17 1
76 Die Holder C58-04A 1
29 Spring (371) 51-17 1
79 Head Insulation RC58-03 1
30 3/16” Ball 16-49 3
31 SI-20 Ring 410-74 1
32 Filter Screen 410-73 1
33 Strainer R150-18 1
34 Vavle Cartridge R150-19B 1
35 S-8 O-Ring R510A-08 1
36 P-7 O-Ring 16-60 1
37 SEPN4 Retainer R150-21 1
38 Plug 51-21 1
39 P-4 Back-Up Ring (B.C.) 410-47 1
40 P-4 O-Ring 410-48 1
41 Spring (341) 51-20 1
42 7/32” Ball 16-26 1
43 M4 X 4 Screw (F.P.) 85-47 3
44 1/8” Ball 40-20 2
45 M5 X 5 Screw (F.P.) 510A-05 1
46 5/32” Ball 22-21 1
47 Body 558-14 1
48 3 X 8 Dowel Pin (D) 610F-11 1