Cembre B54MD-D6 User manual

1
ENGLISH
BATTERY OPERATED
HYDRAULIC CRIMPING TOOL
14 M 174 E
OPERATION AND MAINTENANCE
MANUAL
B54MD-D6
B54MD-D6E
ENGLIS
H
14
M
1
74
E
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ĞƌƟĮĞĚKĐĐƵƉĂƟŽŶĂů
,ĞĂůƚŚΘ^ĂĨĞƚLJ
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
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DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ

2
Before using the tool, carefully read the instructions in this manual.
When operating the tool, keep hands away from the danger zone.
See page 8.
WARNING LABELS
Never throw batteries into fire or water.
Always recycle the batteries.
Do not discard batteries into domestic refuse or waste disposal.
Tool
Battery

3
BATTERY OPERATED HYDRAULIC CRIMPING TOOL
1. GENERAL CHARACTERISTICS
suitable for installing electrical compression connectors
for conductors up to 150 mm2(300 MCM)
54 (6)
340 (4,900)
458 x 133 x 81 (18 x 5.2 x 3.2)
2,95 (6.5)
18
18 / 2.0 Li-Ion
220-240 / 50-60
AGIP ARNICA 22 or ESSO INVAROL EP22 or equivalent.
the tool is equipped with a maximum pressure valve.
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:
Battery charger supply Volt / Hz:
Recommended oil:
Safety:
Types of jaw supplied:
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 EN ISO 5349-1/2 and UNI EN 28662-1
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.
CDD 6 with D3 groove to accept all "W" style crimping dies +
"BG" fixed groove
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
Huskie HT-58 Series
Panduit CD-2001 series
TOOL TYPE: B54MD-D6 B54MD-D6E

4
2. INSTRUCTIONS FOR USE
The tool can be held in one hand while positioning the connector with the other.
Residual battery capacity level is automatically displayed after every cycle.
The part reference includes the following:
– Basic tool complete with crimping jaws with thermoplastic protection.
– Spare battery.
– Battery charger.
– Plastic carrying case type VAL P45.
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. 1)
Grip the tool firmly 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.
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.
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.
9
4
FIG. 1
1

5
2
FIG. 2
P
2.6) Battery status (Ref. to Fig. 2)
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
WHEN THE BATTERY VOLTAGE HAS DROPPED BELOW AMINIMUM SAFETY THRESHOLD, 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 40 minutes.
2.7) Insertion/replacement of battery
To replace the battery, remove it by pressing the release button (15) (Ref. to Fig. 3), then insert the
new battery, sliding it into the guides until it locks.
FIG. 3
2
15
WHEN THE BATTERY VOLTAGE HAS DROPPED BELOW AMINIMUM SAFETY THRESHOLD
,
THE TOOL
WILL NOT START, AND IT IS NECESSARY TO RECHARGE OR REPLACE THE BATTERY.

6
2.9) Jaw replacement
The tool is supplied with the interchangeable CDD 6 jaw.
Other types of jaw 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. 5).
– Fully insert the locking pin (9) into the tool and lock it
by turning clockwise until the red lines are aligned.
red lines
9
FIG. 5
FIG. 4
2.8) ”W” style crimping dies assembles
– Press pins (2) and insert “W” dies into their
seats (see Fig. 4).
– To disassemble them simply press the pins and
slip them from the jaws.
ITIS RECOMMENDED TO USE THE TOOL ONLY
WITH PRODUCT TO BE CRIMPED INSERTED.
2
2

7
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 should be stored and
transported in the plastic case, to prevent damage.
The case is suitable for storing the tool, the
accessories and die sets.
Plastic case: VAL P45,size 497x370x137 mm,
(19.5x14.5x5.4 inches) weighs 2,3 kg (5 lbs.).
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 Certificate supplied by Cembre together with the tool or, if no
other references are available, indicate the approximate purchase date and the tool serial number.
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.
T
HE 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.
O
BSERVE RECOMMENDED REST PERIODS ALSO WHEN USING AN EXTERNAL POWER
SUPPLY.
P
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.
D
O
N
O
T
U
SE THIS T
OO
L
O
N
O
RNEAR ENERGISED C
O
ND
U
CT
O
RS WITH
OU
TPR
O
PER
PERSONAL PROTECTIVE E
Q
UIPMENT. FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN SEVERE INJURY OR DEATH.
T
HE T
OO
LIS
U
NS
U
ITABLE F
O
RC
O
NTIN
UOU
S
U
SE AND SH
OU
LD BE ALL
O
WED T
O
C
OO
L
DOWN FOLLOWING UNINTERRUPTED, SUCCESSIVE CRIMPING OPERATIONS; FOR INSTANCE,
HAVING EXHAUSTED AFULLY CHARGED BATTERY IN ONE SESSION
,
DELAY BATTERY
REPLACEMENT FOR AFEW MINUTES
.
O
BSERVE RECOMMENDED REST PERIODS ALSO WHEN USING AN EXTERNAL POWER
SUPPLY
.
P
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
.

8
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
SPARE PARTS LIST
TABLE 1 (JAW)
Code N° DESCRIPTION
6000630 1 RUBBER COVER 2
6600022 2 DIE RETAINER PIN 2
6520404 3 SPRING 2
6520630 4 SPRING 1
6180171 5 M3 AUTOLOCK NUT 2
6760085 6 Ø 3x12 ELASTIC PIN 2
QtyItem
U 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”.
T 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 effects 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:

9
TABLE 2
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
6000200 11 MECHANICAL GROUP 1
6004168 12 ELECTRONIC CARD 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
6232755 18 TG.0999 LABEL 1
6232500 19 TG.0704 LABEL 1
6232676 20 TG.0919 LABEL 2
QtyItem
5
1
236
5
4
3
2
6
1
CDD6 jaw

10
11
4
12
7
2
1
19
16
20
See TABLE 3

11
20
10
9
18
15
17
8
14
6
1
2
3
13
5
TABLE 2

12
TABLE 3 (ITEM 11 IN TABLE 2)
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
QtyItem

13
Code N° DESCRIPTION QtyItem
6520200 300 65 SPRING 1
6740120 300 66 7/32" BALL 1
3041735 300 67 TIE 2
6640205 300 68 D. 4 SCHNORR WASHER 1
6900052 300 69 M4x6 SCREW 1
6000602 300 70 LEVER SPRING 1
6900054 300 71 M4x6 SCREW 1
6360022 300 72 O-RING 1
6360125 300 75 O-RING 1
6641020 300 77 Ø 6 CU WASHER 1
6000318 300 78 SPRING GUIDE 1
6160081 300 310 BODY 1
6000153 300 350 RESERVOIR CAP 1
6000588 300 360 COMPLETE LEVER SUPPORT 1
6000601 300 400 COMPLETE MEMBRANE 1
6900602 300 500 COMPLETE SUCTION SCREW 1
6000620 600 COMPLETE JAW SUPPORT 1
6000621 600 2 SUPPORT 1
6000632 600 3 ROLL 2
6560200 600 4 PIN ROLL 2
6000622 600 5 JAWS SUPPORT 1
6000623 600 6 SPRING 1
6040564 600 7 RAM GUIDE RING 1
6000624 600 8 PIN GRIP 1
6000633 600 9 JAW LOCKING PIN 1
6700051 600 12 Ø 10 CIRCLIP 1
6900013 600 13 M3x4 SCREW 1
6520030 600 14 RAM RETURN SPRING 1
6520601 600 15 SPRING 1
6760420 600 16 CYLINDRICAL PIN 1
6900180 600 17 M4x10 SCREW 1
TABLE 3 (ITEM 11 IN TABLE 2)

14
24
26
31
19
18
17
75
30
67
16
350
67
64
65
66
310
70
45
63
77
360
71
62
5
4
3
3
12
13
15
16
6
8
17
90
11
600
9
2
1
27
72
69
78
68
*

15
4
19
18
1
250
10
9
20
16
17
15
21
57
400
300
15
100
14
7
500
*
TIGHTENING TORQUE
COUPLE DE SERRAGE
DREHMOMENT
PAR DE TORSION
COPPIA DI SERRAGGIO
8 Nm (5.9 lbf ft)
8
210
11
8
6
11
220
7
9
TABLE 3 (ITEM 11)

16
This manual is the property of Cembre:
any reproduction is forbidden without written permission.
cod. 6261397
Cembre Ltd.
Dunton Park
Kingsbury Road, Curdworth - Sutton Coldfield
West Midlands B76 9EB (UK)
Tel.: [phone] - Fax: [phone]
E-mail: [email protected]
www.cembre.co.uk
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Telefono: 030 36921
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Tél.: [phone] - Fax: [phone]
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