Cembre B54m-d6a User manual

ENGLISH

BATTERY OPERATED

HYDRAULIC CRIMPING TOOL

14 M 168 U

OPERATION AND MAINTENANCE

MANUAL

B54M-D6A

B54M-D6-8A

B54M-KA

NGLI

Certiﬁed Environmental

Management System

Certiﬁed Occupational

Health & Safety

Management System

Certiﬁed Quality

Management System

Before using the tool, carefully read the instructions in this manual.

When operating the tool, keep hands away from the danger zone.

See page 10.

WARNING LABELS

Never throw batteries into re or water.

Always recycle the batteries.

Do not discard batteries into domestic refuse or waste disposal.

Tool

Battery

B54M-D6A

with D3 groove to accept all

"W" style crimping dies +

"BG" xed groove

B54M-D6-8A

with D3 groove to accept all

"W" style crimping dies + "O"

xed groove

B54M-KA

with groove to accept all "O"

style Kearny crimping dies.

Adapter to accept all "W" style

crimping dies available as an

accessory

style

FIG. 1

The part reference includes the following:

– Basic tool complete with battery.

– Spare battery.

– Battery charger (model depends on the tool version).

– Plastic carrying case.

BATTERY OPERATED HYDRAULIC CRIMPING TOOL

1. GENERAL CHARACTERISTICS

TOOL TYPE:

Acoustic Noise (Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u)

– The weighted continuous acoustic pressure level equivalent

A at the work place LpA is equal to .............................................................................................................. 64,9 dB (A)

– The maximum value of the weighted acoustic displacement

pressure C at the work place LpCPeak is equal to ........................................................................................ 99,7 dB (C)

– The acoustic power level emitted by the machine

LWA is equal to ...................................................................................................................................................... 69,3 dB (A)

Risks due to vibration (Directive 2006/42/EC, annexe 1, point 2.2.1.1)

Tests carried out in compliance with the indications contained in UNI ENV 25349 and UNI EN 28662 part

1st Standards, and under operating conditions much more severe than those normally found, certify that

the weighted root mean square in frequency of the acceleration the upper limbs are exposed to for

each biodynamic reference axis is 0,527 m/sec2 max.

Application range:

Crimping force kN (sh ton):

Rated operating pressure bar (psi):

Dimensions

LxWxH

mm (inches):

Weight with battery kg (lbs):

Motor Volt DC:

Battery

type

CB1820L Volt / Ah:

Recommended oil:

Safety:

Operating temperature °C (°F):

Types of jaw supplied:

(see table A page 10 for compatibility)

Battery charger ASC30-36

Input Volt / Hz:

suitable for installing electrical compression connectors

for conductors up to 150 mm2(300 MCM)

54 (6)

340 (4,900)

18 / 2.0 Li-Ion

AGIP ARNICA 22 or

ESSO INVAROL EP22

or equivalent.

the tool is equipped with a maximum pressure valve.

-15 to +50 (+5 to +122)

USA/CAN 27046000

115 / 60

B54M-D6A B54M-D6-8A B54M-KA

CDD 6

with D3 groove to

accept all "W" style

crimping dies +

"BG" xed groove

CDD 6-8

with D3 groove to

accept all "W" style

crimping dies + "O"

xed groove

CDK

with groove to

accept all "O"

style Kearny

crimping dies

445 x 133 x 81

(17.5 x 5.2 x3.2)

458 x 133 x 81 (18 x 5.2 x3.2)

3,02 (6.6)2,95 (6.5)

2. INSTRUCTIONS FOR USE

The tool is equipped with automatic return of the dies once the crimping operation is completed.

The interchangeable crimping jaws have thermoplastic rubber covers on outside edges.

Residual battery capacity level is automatically displayed after every cycle.

The part reference “B54...” includes the following:

– Basic tool complete with battery

– Spare battery

– Battery charger

– Canvas bag.

2.1) Preparation

With the tool in the rest position (the ram fully retracted) proceed as follows:

– Select the appropriate groove or die set for the connector to be crimped.

– Insert the dies into the jaws of the tool (see § 2.8).

– Insert the conductor into the connector.

2.2) Die advancement (Ref. to Fig. 2)

Grip the tool rmly and comfortably.

– Position the connector in the die groove

and ensure the correct location of the

crimp.

– Press operating button (4) to activate

the motor-pump group for the advance-

ment of the ram. To halt the advance-

ment, release the operating button and

the motor will cut out.

Make sure the dies are exactly positioned

on the desired crimp point otherwise

re-open dies following instructions as per

§ 2.5 and reposition the connector.

FIG. 2

FIG. 3

2.3) Compression

Insert the conductor in the connector and press the operating button (4): the ram will gradually

move forward until the two dies touch. It is recommended to keep operating until the maximum

pressure valve is activated and a "click" is heard, after which the dies will automatically re-open

until the ram is fully retracted. It is always possible to interrupt automatic retraction of the ram by

a short push on the operating button (4).

2.4) Head rotation

For ease of operation the tool head can rotate through 180°, allowing the operator to work in the

most comfortable position.

Warning: do not attempt to rotate the head when the hydraulic circuit is pressurised.

2.5) Release of dies

Press the pressure release button (9), the ram will retract and open the jaws.

2.6) Battery status (Ref. to Fig. 3)

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 ashing: Minimum charge, replace the battery

FIG. 4

2.7) Insertion/replacement

of battery

To replace the battery, remove

itbypressingthe release button

(15)(Ref.toFig.4),theninsertthe

new battery, sliding it into the

guides until it locks.

2.8) Crimping die assembles

2.8.1) Use of ”W” style crimping dies (B54M-D6A, B54M-D6-8A tools)

– Press pins (2) and insert “W” dies into their seats (see Fig. 5A).

– To disassemble them simply press the pins and slip them from the jaws.

2.8.2) Use of ”O” style Kearney crimping dies (B54M-KA tool)

– Insert “O”dies into their seats, the two dies will be held by the retainers (7) (see Fig. 5B).

– To disassemble them simply slip them from the jaws.

Note: it is possible to use “W”style crimping dies with B54M-KA by means of the AU55-B adapter,

available as an accessory.

ITIS RECOMMENDED TO USE THE TOOL ONLY WITH PRODUCT TO BE CRIMPED INSERTED.

"W" style crimping dies "O" style crimping dies

FIG. 5A

B54M-D6A, B54M-D6-8A tools

FIG. 5B

B54M-KA tool

2.9) Jaw replacement

Each tool is supplied with relevant jaws (see § 1). Jaws can

also be supplied separately, for replacement proceed as

follows:

–Push and turn clockwise the locking pin (9) so that

the jaws are released.

– Slide the jaws out of the top of the tool and insert the

new ones (see Fig. 6).

– Fully insert the locking pin (9) into the tool and lock it

by turning clockwise until the red lines are aligned.

red lines

FIG. 6

3. WARNING

Before starting work on electrical equipment, please ensure that either there are no live parts in

the immediate working area or that precautions are taken for working near live parts in accordance

with EN50110-1.

DONOT USE THIS TOOL ON OR NEAR ENERGISED CONDUCTORS WITHOUT PROPER

PERSONAL PROTECTIVE EQUIPMENT. FAILURE TO OBSERVE THIS WARNING COULD

RESULT IN SEVERE INJURY OR DEATH.

THE TOOL IS UNSUITABLE FOR CONTINUOUS USE AND SHOULD BE ALLOWED TO COOL

DOWN FOLLOWING UNINTERRUPTED, SUCCESSIVE CRIMPING OPERATIONS; FOR INSTANCE,

HAVING EXHAUSTED AFULLY CHARGED BATTERY IN ONE SESSION, DELAY BATTERY

REPLACEMENT FOR AFEW MINUTES.

OBSERVE RECOMMENDED REST PERIODS ALSO WHEN USING AN EXTERNAL POWER

SUPPLY.

PROTECT THE TOOL FROM RAIN AND MOISTURE. WATER WILL DAMAGE THE TOOL AND

BATTERY. ELECTRO-HYDRAULIC TOOLS SHOULD NOT BE OPERATED IN POURING RAIN

OR UNDER WATER.

DONOT USE THIS TOOL ON OR NEAR ENERGISED CONDUCTORS WITHOUT PROPER

PERSONAL PROTECTIVE EQUIPMENT.

AILURE TO OBSERVE THIS WARNING COULD

ULT IN

EVERE INJURY

RDEATH.

HE T

LIS

ITABLE F

NTIN

UOU

SE AND SH

LD BE ALL

WED T

DOWN FOLLOWING UNINTERRUPTED

SUCCESSIVE CRIMPING OPERATIONS

;

FOR INSTANCE

HAVING EXHAU

TED AFULLY

HARGED BATTERY IN

DELAY BATTERY

REPLACEMENT FOR AFEW MINUTES.

OBSERVE RECOMMENDED REST PERIODS ALSO WHEN USING AN EXTERNAL POWER

UPPLY

ROTECT THE TOOL FROM RAIN AND MOISTURE. WATER WILL DAMAGE THE TOOL AND

BATTERY

ELECTRO-HYDRAULIC TOOLS SHOULD NOT BE OPERATED IN POURING RAIN

OR UNDER WATER.

3.1) Using the battery charger

Carefully follow the instructions in the battery charger manual.

4. MAINTENANCE

The tool is robust, completely sealed and requires very little daily maintenance.

Compliance with the following points should help to maintain the optimum performance of

the tool:

4.1) 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 moveable parts.

4.2) Storage

When not in use, the tool and accesories should be stored and transported in the relevant canvas

bag to prevent damage.

SER INFORMATION in accordance with “Directives 2002/95/EC and

2002/96/EC regarding the reduction of hazardous substances in electrical and

electronic equipment, including the disposal of waste”.

he 'Not in the bin' symbol above when shown on equipment or packaging

means that the equipment must, at the end of its life, be disposed of separately

from other waste.

The separate waste collection of such equipment is organised and managed by

the manufacturer.

Users wishing to dispose of such equipment must contact the manufacturer and

follow the prescribed guidelines for its separate collection.

Appropriate waste separation, collection, environmentally compatible treatment

and disposal is intended to reduce harmful environmental eects and promote

the reuse and recycling of materials contained in the equipment.

Unlawful disposal of such equipment will be subject to the application of admin-

istrative sanctions provided by current legislation.

- Following information applies in member states of the European Union:

INTERCHANGEABLE CRIMPING JAWS

JAW TYPE GROOVES CRIMPING DIE COMPATIBILITY

CDD6 “D3”TO ACCEPT ALL“W” STYLE

CRIMPING DIES + “BG” FIXED GROOVE

FCI Burndy W, X Series

Greenlee KD6 Series

Ilsco ND Series

CDD6-8 “D3”TO ACCEPT ALL“W” STYLE

CRIMPING DIES + “O”FIXED GROOVE

Huskie HT-58 Series

Panduit CD-2001 series

CDK

GROOVE TO ACCEPT ALL“O” STYLE

KEARNEY CRIMPING DIES

AU55-B ADAPTER TO ACCEPT ALL“W”

STYLE CRIMPING DIES AVAILABLE AS AN

ACCESSORY

FCI Burndy W, X Series

Greenlee KD6 Series

Ilsco ND Series

Huskie HT-58 Series

Panduit CD-2001 Series

Kearney O Series

Blackburn 6 tons

TABLE A

The guarantee is void if parts used are not

Cembre

original spares.

When ordering spare parts always specify the following:

- code number of item

- name of item

- type of tool

- serial number of tool

TABLE 1

SPARE PARTS LIST

5. 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 pos-

sible, attach a copy of the Test Certicate supplied by

Cembre

together with the tool or, if no

other references are available, indicate the approximate purchase date and the tool serial number.

Code N° DESCRIPTION

6000577 1 BODY RIGHT+LEFT SHELL 1

6000128 2 BATTERY ADAPTER SHELL R+L 1

2598495 3 BATTERY CB1820L Li-Ion 18V 2Ah 1

6000217 4 OPERATING BUTTON 1

6000127 5 SHUTTER 1

6000591 6 ROD 1

6000593 7 SPRING 1

6000150 8 CONTACT SUPPORT 1

6000218 9 PRESSURE RELEASE BUTTON 1

6000582 10 BUTTON STRIKER 1

6006255 11 MECHANICAL GROUP 1

6004168 12 COMPLETE ELECTRICAL CIRCUIT 1

6000126 13 SHUTTER 1

6000589 14 WRIST STRAP 1

6006280 15 BATTERY RELEASE 1

6900650 16 3,5X16 SCREW 8

6520531 17 SPRING 1

6232746 18 TG.0990 LABEL 1

6232500 19 TG.0704 LABEL 1

6232676 20 TG.0919 LABEL 2

QtyItem

See TABLE 2

TABLE 1

TABLE 2 (ITEM 11 IN TABLE 1)

Code N° DESCRIPTION

6000625 90 RUBBER GRIP 1

6000199 100 ACTUATING MECHANICAL GROUP 1

6000357 100 1 HOUSING 1

6000358 100 4 GEAR 1

6760004 100 8 Ø 2X8 CYLINDRICAL PIN 3

6900008 100 9 M3x6 SCREW 2

6000849 100 10 Ø 3 SCHNORR WASHER 2

6740020 100 11 1/4" BALL 2

6000363 100 15 GEAR 3

6402009 100 16 BEARING 1

6402006 100 17 WASHER 1

6000328 100 18 WASHER 1

6760012 100 19 CYLINDRICAL PIN 2

6000315 100 20 SPACER 3

6000231 100 210 COMPLETE DISC 1

6000229 100 6 DISC 1

6000227 100 7 BALLS SUPPORT 1

6700080 100 8 Ø 6 CIRCLIP 1

6650136 100 9 WASHER 1

6000232 100 220 COMPLETE CAM 1

6000198 100 250 COMPLETE MOTOR 1

6000152 300 COMPLETE HYDRAULIC GROUP 1

6620122 300 1 RAM 1

6362098 300 11 SEAL 1

6000560 300 15 MEMBRANE RING 1

6720072 300 16 OIL RESERVOIR 1

6300027 300 17 VALVE PISTON 1

6000561 300 18 GRUB SCREW 1

6520232 300 19 VALVE SPRING 1

6620378 300 21 PUMPING RAM 1

6000563 300 24 VALVE ROD 1

6000575 300 26 SPRING SUPPORT 1

6000565 300 27 TEST PRESSURE CAP 1

6641027 300 30 WASHER 1

6000567 300 31 SETTING VALVE LOCKNUT 1

6000603 300 45 PRESSURE RELEASE LEVER 1

6000570 300 57 PUMPING RAM RETURN SPRING 1

6740100 300 62 5/32" BALL 1

6520160 300 63 SPRING 1

6340590 300 64 GRUB SCREW 1

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TABLE 2 (ITEM 11 IN TABLE 1)

350

310

360

600

320

250

400

300

100

500

TIGHTENING TORQUE

COUPLE DE SERRAGE

DREHMOMENT

PAR DE TORSION

COPPIA DI SERRAGGIO

8 Nm (5.9 lbf ft)

210

220

TABLE 2 (ITEM 11)

236

CDD6 jaw

Item DESCRIPTION

2REVOCREBBUR1136000603600060360006 2NIPRENIATEREID2220006622000662200066 2GNIRPS3404025640402564040256 1GNIRPS4036025603602560360256 2TUNKCOLOTUA3M5171081617108161710816 2NIPCITSALE21x3Ø6580067658006765800676 2RENIATEREID77000426--

CDD6 CDD6-8 CDK

QtyCode N°

TABLE 3 (JAW)