Cembre B-TC500YA User manual

1
18 M 122 U
BATTERY OPERATED HYDRAULIC
CUTTING TOOL
B-TC500YA B-TC500YNA
OPERATION AND MAINTENANCE MANUAL
ENGLISH

2
Cu Al
4
Low battery
5
5
FIG. 3
FIG. 2
FIG. 4
1
1
3
FIG. 3a
12
15
3
2
19
17
4
20
13
4
11
14
21
18
16
3
FIG. 1b
Makita battery
FIG. 1a
Metabo
battery
10
10

3
1
LED WORKLIGHT
2
UPPER BLADE
3
LOWER BLADE
4
LATCH
5
OPERATING BUTTON
6
PRESSURE RELEASE BUTTON
7
BATTERY
8
BATTERY RELEASE
9
RING FOR SHOULDER STRAP
10
BATTERY ADAPTER
FIG. 5
5
6
7
8
2
1
1
9
3
4
5
6
7
8
2
1
1
9
3
4
10

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– Before using the tool, carefully read the instructions in this manual.
– Keep hands clear of cutting blades.
– Always wear safety glasses and gloves when operating this tool.
WARNING SYMBOLS
– Never throw batteries into re or water.
– Always recycle the batteries.
– Do not discard batteries into domestic refuse or waste disposal.
– User information (Directives 2011/65/EU and 2012/19/EU), see page 9.
Battery
Tool
(
(
(
(
(
(
(
(
– Do not cut Steel.

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1. GENERAL CHARACTERISTICS
(1) Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u
LpA = weighted continuous acoustic pressure level equivalent.
LpCPeak = maximum value of the weighted acoustic displacement pressure at the work place.
LWA = acoustic power level emitted by the machine.
(2) Directive 2006/42/EC, annexe 1, point 2.2.1.1
Weighted root mean square in frequency of the acceleration the upper limbs are exposed to for each biodynamic
referenceaxis.TestscarriedoutincompliancewiththeindicationscontainedinEN ISO 5349-1/2 Standards, andunder
operating conditions much more severe than those normally found.
B-TC500YA B-TC500YNA
Application range suitable for cutting Copper, Aluminium
or telephone cables
Max. cutting diameter mm (inches) 50 (2”)
Operating pressure bar (psi) 600 (8,700)
Dimensions (Fig. 6 and g. 7
page 10)
mm (inches) 405 x 398 x 83
(15.9 x 15.6 x 3.3)
405 x 418 x 83
(15.9 x 16.5 x 3.3)
Weight with battery kg (lbs) 5,8 (12.7) 5,9 (13)
Motor V DC 18
Operating temperature °C (°F) -15 to +50 (+5 to +122)
Recommended oil AGIP ARNICA 32 or equivalents.
Operating speed twin speed operation and automatic switching from
a rapid advancing speed of the ram to a slower, more
powerful crimping speed
Safety maximum pressure valve
Rechargeable battery type CB1840L MAKITA BL1840B
Type V / Ah (Wh) 18 / 4.0 / (72) 18 / 4.0 / (72)
Weight kg (lbs) 0,66 (1.45) 0,6 (1.3)
Acoustic noise (1)
LpA dB (A)
73
LpCPeak dB (C) 94.5
LWA dB (A) 79
Vibration (2) m/s20.575 max.
Battery charger
Input
type
V / Hz
ASC30-36 MAKITA DC18RC
115 / 60 120 / 50 - 60

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WARNING
This tool has been specically designed for cutting Copper, Aluminium and ACSR conductors.
DO NOT ATTEMPT TO CUT STEEL ROPES, GUY WIRE OR EARTHING ROD.
Do not use the tool for purposes other than those intended by Cembre.
The operator should concentrate on the work being performed and be careful to maintain a bal-
anced working position.
Work in a clean, uncluttered area. Keep persons away from immediate work area.
Inspect the blades before each use. Do not use damaged blades.
Damaged blades can break and cause injury or damage to the tool.
Before each use, verify the integrity of the tool; replace any worn, possibly damaged or missing
parts with original Cembre spares.
Wear eye protection. Metal chips can y from blades when cutting.
Do not cut live cables or conductors.
The tool is unsuitable for continuous use and should be allowed to cool down following uninter-
rupted, successive cutting operations; for instance, having exhausted a fully charged battery in
one session, delay battery replacement for a few minutes.
Protect the tool from rain and moisture. Water will damage the tool and battery.
Electro-hydraulic tools should not be operated in pouring rain.
The part reference includes the following (Ref. to Fig. 8):
Hydraulic cutting tool (B-TC500YNA is tted with adapter to use Makita battery).
Li-Ion rechargeable battery (2 pcs) (model depends on the tool version).
Battery charger (model depends on the tool version).
Shoulder strap.
Plastic carrying case.
Cavo USB (Rif. al § 5).
2. INSTRUCTIONS FOR USE
The tool can be easily carried using either the handle or the shoulder strap attached to ring (9)
(Ref. to Fig. 5).
Before starting any work, check the battery charge (Ref. to § 2.7) and recharge if necessary,
following the instructions in the battery charger user manual.

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To replace the battery, remove it by pressing the release button (8) (Ref. to Fig. 1), then insert the
new battery, sliding it into the guides until it locks.
2.1) Head rotation
Foreaseofoperation, the toolheadcan rotate,allowingtheoperatortoworkinthe most comfortable
position (Ref. to Fig. 3).
Do not attempt to rotate the head when the hydraulic circuit is pressurised.
2.2) Setting
Insert the conductor between the blades, up to the desired cutting point (Ref. to Fig. 3).
To cut short pieces of ACSR ropes, it is suggested to tie or wrap rope with adhesive or duct
tape around the area to be cut and at its end, so to limit the projection of steel fragments
which could damage or hurt the operator.
For a running conductor, release the latch (4) and open the tool head (Ref. to Fig. 3a).
Fully retract the lower blade (3) before attempting to open the tool head (Ref. to § 2.6).
With the conductor on the lower blade (3), close the tool head and fully secure the latch (4).
Before commencing the cutting operation ensure that the latch (4) is fully secured: partial
closure may damage the tool head.
2.3) Blade advancement
Press the operating button (5) (Ref. to Fig. 3) to activate the motor-pump, the ram will gradually
move forward until the lower blade (3) touches the conductor.
To halt the advancement, release the button (5) and the motor will cut out.
2.4) Cutting
Firmly hold the tool and operate the button (5) to gradually move the lower blade (4) to cut
through the conductor.
When the cut is performed, release the push-button (5), otherwise after the maximum pressure
relief valve has activated the motor will stop automatically.
2.5) LED Worklights
Whilst the tool is in operation, the work areais illuminated by two high luminosity LED Worklights
that switch o automatically at the end of the cycle.
2.6) Blade retraction
By operating the pressure release button (6), the ram will retract and open the lower blade.

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2.7) Battery status
The battery is equipped with LED indicators that indicate the
remaining battery life at any time by pressing the adjacent
button (P):
4 LEDs illuminated: fully charged
2 LEDs illuminated: 50 % capacity
1 LED flashing: minimum charge, replace the battery
Worklights (1) illuminated combined with an alarm au-
dible when the operating button (5) is pressed (Ref. to
Fig. 2), indicate that the battery voltage has dropped below a minimum safety threshold;
under these conditions the tool will not start, and it is necessary to recharge or replace the battery.
The approximate time to fully recharge a battery is about 80 minutes.
After each working cycle, and after the extraction of the battery from the tool, an integrated
battery cut-o device will operate after 70 s approx. Then the LED nearest to button (P) will
ash 5 times each 14 s approx. The battery will be reactivated when it is reintroduced into
the tool and the operating button is pressed.
2.8) Using the battery charger
Carefully follow the instructions in the battery charger user manual.
3. MAINTENANCE
The tool is robust, completely sealed, and requires very little daily maintenance. Compliance with
the following points, should help to maintain its optimum performance:
3.1) Thorough cleaning
Dust, sand and dirt are a danger for any hydraulic device. Every day, after use, the tool must be
wiped with a clean cloth taking care to remove any residue, especially close to pivots and move-
able parts.
Do not use hydrocarbons to clean the rubber parts.
Regularly lubricate the moving parts and pivot pins of the head with a few drops of oil.
3.2) Storage case
When not in use, the tool should be stored and transported in the plastic case, to prevent damage.
The case, type VAL-P40, is suitable for storing the tool and accessories.
VAL-P40: Size 520x432x126 mm (20.5x17.0x5.0 inches). Weight 2,6 kg (5.7 lbs).
3.3) Routine maintenance
When the tool reaches the predetermined number of hours worked, it will signal that routine
maintenance is recommended.
The tool will continue to work however 15 sec. after use an alarm comprising 3 beeps com-
bined with illumination of the worklights will signal that its return to Cembrefor service is
recommended(see § 6).
P

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4. BLADE REPLACEMENT (Ref. to Fig. 4)
When changing blades, the battery must rst be removed from the tool.
After extended use, the blades may lose their cutting edge. Replace the blades as follows:
Lower blade
– Release latch (4) and open the tool head.
– Operate tool to advance the lower blade (3) until split pins (12) are visible on the ram (11), than
remove the battery from the tool.
– Remove 2 split pins (12) using a drift and remove the lower blade (3).
– Insert the new blade and re-t by 2 split pins.
Before closing the tool head, release the oil pressure and retract the lower blade, otherwise
the tool head assembly may hit and damage the lower blade.
Upper blade
– Release latch (4) and open the tool head.
– Remove the circlip (17) and extract the head pivot (13), enough to release the tool head assembly.
– Remove circlip (21) and pivot pin (20), to release the latch (4).
Remove latch spring (16) from the upper blade (2).
– Unscrew the 4 screws (19) and remove the left hand guide (14) and the right hand guide (15)
release the blade (2).
– Fit the left and right hand guides to the new blade, place the spring (16) into its seat and re-t
the latch (4).
– Fit the blade assembly to the head (18), fully insert the pivot (13) and secure with the circlip (17).
5. CONNECTION TO COMPUTER
The memory card integrated in the tool records operating data from 200.000 cycles for transfer via
the USB cable supplied.
To view and manage this data, go to www.cembre.com and register in the dedicated area, then
download the free Cembre software CEM_SWBT01.
Keeping the Firmware of the tool updated, via free of charge download from here, will optimise
the tool's performance.
6. RETURN TO Cembre FOR OVERHAUL
In the case of a breakdown contact our Area Agent who will advise you on the problem and give
you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible,
attach a copy of theTest Certicate supplied by Cembretogether with the tool or ll in and attach
the form available in the“ASSISTANCE” section of the Cembre website.

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405 (15.9)
398 (15.6)
83 (3.3)
405 (15.9)
418 (16.5)
83 (3.3)
FIG. 6 mm (inch) B-TC500YA
FIG. 7 mm (inch) B-TC500YNA