Cembre B68M-P18A-KV-RC2 User manual

1
ELECTRO-HYDRAULIC BATTERY PUMP
RADIO CONTROLLED
Cerfied Environmental
Management System
Cerfied Occupaonal
Health & Safety
Management System
Cerfied Quality
Management System
18 M 033 U
B68M-P18A-KV-RC2
ENGLISH OPERATION AND MAINTENANCE MANUAL

2
FIG. 2
A
G
F
C
B
FIG. 1
1
5
9
10
12
8
7
3
2
4
2
11
D
6
E

3
TC085Y-KV-RC2
TC096Y-KV-RC2
TC120Y-KV-RC2
FIG. 3
6
5
4
3
2
1
7
3
1
6
5
7
5
7
1
6
3
2
2
8
5
FIG. 4
example of a cutting opera-
tion within a manhole with
user at a safe distance away.

4
CLICK
~ 0 %
50 %
100 %
Battery
FIG. 6
3
FIG. 5
FIG. 7
P
Female
Quick coupler
Male
Quick coupler
Female
Quick coupler
Male
Quick coupler
Cutting
head ..RC2
Battery pump ...RC2
Flexible
insulated hose
1
2

5
1/2" -13 UNC
Thread
1/2" -13 UNC
Thread
16
6
grounding wire *
* purchase separately
TC085Y-KV-RC2
TC120Y-KV-RC2
8
4
6
16
17
2
FIG. 8
FIG. 9
FIG. 10
FIG. 11
SS-TCY strap *
2
connect the other end of the grounding wire to
a suitable grounding point
grounding wire *

6
FIG. 13
212 (7.3)
236 (9.3)
350 (13.8)
405 (15.9)
mm (inch)
OIL
1
Max. oil level
FIG. 12
1
WARNING : use dielectric oil only.
For type and quantity refer to
section 1, page 9.

7
Hydraulic pumps manufactured by Cembre S.p.A. are developed for use with hydraulic heads.
According to this specific use, they do not need and are not equipped with an oil non-return safety
system.
For this reason, use in applications different from those intended (for example with hydraulic jacks,
lifting systems or similar) can be dangerous for the operator.
Cembre S.p.A. does not accept any liability arising from the use of its hydraulics pumps for ap-
plications different from those listed in its catalogues or other documentation.
Do not use the pump for purposes other than those intended by Cembre S.p.A.
The operator should concentrate on the work being performed and be careful to maintain a ba-
lanced working position.
Avoid dirty surfaces: dust and sand are a danger to any Electro-hydraulic equipment.
Protect the pump and accessories from rain and moisture. Water will damage the pump and battery.
The flexible hydraulic hose supplied should always be used to connect the hydraulic head to the
pump. The hydraulic head should never be directly connected to the pump.
The pump contains dielectric oil which must not be polluted with any other types of oil.
Never connect to the pump any hydraulic heads which still contains oil, this can occur if the ram on
the hydraulic head has not been fully retracted; excess oil could cause the pump to malfunction.
Before disconnecting the flexible hose, check that the ram of the head is completely retracted, in
order to ensure that a sufficient quantity of oil is available for subsequent operations.
The pump is unsuitable for continuous use and should be allowed to cool down following uninter-
rupted, successive crimping operations; for instance, having exhausted a fully charged battery in
one session, delay battery replacement for a few minutes.
WARNINGS

8
Use and Care of rechargeable batteries
Recharge the supplied battery using the specific manufacturer’s charger only.
A charger intended for a specific type of battery may become a fire hazard if used with other types
of battery.
Use the tool with the specific intended battery pack only, the use of any other type of battery may
lead to a risk of injury or fire.
When the battery is not in use, store it away from other metal objects, such as paperclips, coins,
keys, nails, screws or other small metal objects that can create a connection between two terminals.
Keep batteries out of reach of children.
Short-circuiting the battery terminals can cause burns or fire.
If in very poor condition, a battery can leak liquid. Avoid contact with the eyes.
In the case of accidental contact, rinse immediately under running water.
If the liquid comes into contact with the eyes, seek medical assistance immediately. Battery liquid
can cause irritation or burns.
Keep batteries dry!
Keep batteries away from fire!
Never throw batteries into fire or water.
Always recycle batteries after use.
Never dispose of batteries with household waste; they must be deposited at the dedicated
collection points for disposal.
Transporting Li-Ion batteries
Lithium-Ion rechargeable batteries are subject to the legal requirements on hazardous goods. In the
event of road transport by the user, no further precautions are necessary.
In the event of third-party transport (e.g. transported by airplane or courier), transportation must
comply with the special requirements concerning packaging and labelling. We recommend that
you consult an expert.
Rechargeable batteries can only be transported if undamaged.
The packaging must prevent the batteries from moving around and exposed contacts must be
covered with adhesive tape.
I MPORTANT: Before using
the equipment, carefully
read all the warnings
and instructions in this
manual. Failure to follow
the warnings and instruc-
tions may result in electric
shock, fire and/or serious
injury.
When operating
the pump, keep
hands away from
the danger zone.
PUMP WARNING LABEL
TG.0932
TG.0932


User information
(Directives
2011/65/UE and
2012/19/UE), see
page 28.
TG.0932
TG.0932
Always wear safety
gloves when ope-
rating the equip-
ment.



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


9
(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
reference axis. Tests carried out in compliance with the indications contained in EN ISO 5349-1/2 Standard, and
under operating conditions much more severe than those normally found.
1. ELECTRO-HYDRAULIC BATTERY PUMP (RADIO CONTROLLED)
Operating pressure psi (bar) 10,573 (729)
Oil supply
high speed - low pressure
low speed - high pressure
US gpm (l/m)
US gpm (l/m)
0.34 (1,28)
0.07 (0,25)
Motor V DC 18
Radio receiver frequency
remote control
cutting head blade travel sensor
Mhz
Mhz
2405–2480
915 (USA CANADA AUSTRALIA)
Operating temperature °F (°C) +5 to +122 (-15 to +50)
Oil reservoir capacity cu. in. (cm3)58.6 (960)
Recommended dielectric oil TOTAL DIEKAN 1640
Operating speed Double speed action: operation and automatic
switching from a rapid advancing speed to a slower,
more powerful working speed
Degree of protection IP 20
Dimensions Ref. to Fig. 13 page 6
Weight with battery lbs (kg)
12.8 (5,8)
Safety double safety system,
electronic & mechanical safety valve
Acoustic noise (1) dB LpA 66.8 (A) LpCPeak 88 (C) LWA 82.8 (A)
Vibrations (2) m/s20.318
Rechargeable battery type CB1870L Li-Ion
V / Ah (Wh) 18 / 7.0 (126)
Weight lbs (kg) 2 (0,9)
Battery charger ASC30-36
Input
type USA/CAN
V / Hz (W) 115 / 60 (85)

10
1.1) Compliance of use
- The B68M-P18A-KV-RC2 pump is designed to activate hydraulic heads for cutting conductor
cables or for crimping electrical cable lugs.
- The pump, when used with specifically designed cutting heads, allow for the safe cutting of
Copper and Aluminum cable where the absence of voltage cannot be guaranteed.
- The dielectric oil used within the pump has special properties which insulate the pump from
the cutting head in the event that a live cable is accidentally cut.
- The innovative radio remote control is designed specifically for use within manholes allowing
the operator to control and operate the pump outside of the manhole at a safe distance away
from the cutting operation.
- The complete unit (pump & cutting head) is fitted with a unique patented system which stops
the pumps operation when a sensor on the cutting head signals that the cutting blades have
fully travelled.
At this point the LED indicator and buzzer on the pump notify the operator of the successful
completion of the cutting operation. For this reason, each pump is paired to its specific cutting
head only and it must be considered as a complete unit.
For the proper operation of all the safety features in the complete unit, each cutting
head is paired to its associated pump. This procedure is completed by Cembre prior
to delivery. Due to this, the use of non-paired pumps and cutting heads is not recom-
mended and should be avoided. In order to trace all of the components of each complete unit,
such as: pump, cutting heads, radio control, the user should check the identification number
reported on the tag attached to each item.
1.2) Description
B68M-P18A-KV-RC2 includes the following (Ref. to Fig. 1):
(A) Canvas bag: made from sturdy fabric, allows users to store the pump and accessories.
(B) Battery charger: for recharging the batteries supplied; has“AIR COOLED”charging technol-
ogy and a processor for managing charging cycles.
To use, carefully follow the instructions in the battery charger user manual.
(C) USB cable: for transferring the data stored on the internal memory card to a PC.
(D) Rechargeable battery (2 pcs): 18 V - 7.0 Ah high capacity Lithium Ion battery.
Provides 100% of its energy between +5 and +122 °F (-15 and +50 °C).
Electronic control of the individual cells to prevent over-charging and under-discharging.
Greater longevity and ventilated recharging in short times thanks to AIR COOLED technology.
Timed automatic power off to optimize energy consumption.
Equipped with LED indicators that indicate the remaining battery life at any time by pressing
the button (P) (Ref. to Fig. 5):
4 LEDs illuminated: fully charged
2 LEDs illuminated: 50 % capacity
1 LED flashing: minimum charge, replace the battery.

11
With the battery inserted in the pump, the remaining battery
life can also be checked on the display, via touch button
selection (Ref. to section 7).
The display alongside indicates that the battery is low and the
pump will not start (Ref. to section 7.5).
The approximate time to fully recharge a CB1870L battery is about 150 minutes.
(E) Shoulder Strap: allows for easy transportation of the pump when connected to the rings
(2) on the pump.
It can also be used to secure the pump to the ladder in the manhole or to the manhole guard.
(F) Radio Remote Control RRC1: allows users to control the pump from a safe distance.
(Ref. to section 2 for further details).
(G) Portable hydraulic high capacity pump: driven by an 18V battery powered electric motor.
An Electronic Pressure Sensor (EPS) ensures precision and repeatability of the work cycles and
a maximum pressure valve to ensure maximum operator safety.
The pump features a double safety control: hydraulic pressure and blade travel sensor signal.
The memory card integrated into the pump allows the storage of the data relating to previous
operating cycles.
The default settings of the pump are:
Operating mode: CUTTING (Ref. to section 7.2 to choose CRIMPING operating mode).
Oil release mode: SMART (Ref. to section 7.3 for further details).
Pump control mode: RADIO ON, enables the radio remote control (Ref. to section 7.4 for
further details).
Main components (Ref. to Fig. 2):
1- OIL FILLER CAP: for accessing the pump’s oil tank.
2- STRAP FASTENING RING: to attach the shoulder strap and transport the pump.
It can be used to hang the radio control before the storage of the pump.
3- BATTERY RELEASE DEVICE: to lock/unlock the battery, press the button (3) and push the battery
downward to unlock it (Ref. to Fig. 6). Insert a battery from the bottom by sliding it into the
side guides until it locks.
4 - LED INDICATOR: to visually indicate to the operator the progress and the conclusion of the
cutting operation or to notify the operator of procedural or operational errors.
5- BUZZER: synchronized with the LED indicator to indicate audibly the operation in pro-
gress or to notify the operator of procedural or operational errors.
6- RADIO RECEIVER BOX: includes the radio receivers of the remote control and of the blade
travel sensor.
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........

12
7- MECHANICAL PRESSURE RELEASE BUTTON: if required, by
pressing hard on the mechanical pressure release button,
the oil can be returned to the reservoir at any time, regard-
less of the status of the battery.
8- I38F AUTOMATIC QUICK COUPLER: enables connection of
the insulated flexible hose. In order to attach or disconnect
the hose, pull the ring back.
The couplers cannot be disconnected if the system is under pressure.
The anti-dust protection cap must be used on both the hose and pump couplings to prevent
ingress of dirt or contamination.
9- CAPACITIVETOUCH BUTTON: for menu selection allows selection of various screens only when
the display is on (Ref. to section 7).
Do not apply pressure to or stab at the touch button, a light touch using a bare finger
is sufficient. The command pulse is sent when the finger releases the button.
The capacitive touch button may not work if touched using objects or when wearing
gloves, therefore always operate it using a bare finger.
10 - OLED DISPLAY: switches on when the control button (11) on the pump is pressed forward
and off automatically after 1 hour of non-operation.
11- CONTROLBUTTON:rocker type,push forwardonce to wake
up the pump and turn on the display.
NOTE: if required the control button can be used to activate
the pump motor or release the oil in manual mode instead
of the RRC1 radio remote control.
By default setting this function is disabled, to enable refer
to section 7.4.
12 - HANDLE: for safe and balanced transportation of the pump.
11
release
start
7

13
2
1
3
7
6
5
4
FRONT BACK
+
+
-
-
RRC1
RADIO REMOTE CONTROL
PUMP RELEASE
ON/OFF
ON/OFF
2. RRC1 RADIO REMOTE CONTROL
FEATURES:
frequency band: 2405–2480 MHz
battery: 2 x 1.5V AAA / LR03 Alkaline
dimensions: 2.6 x 4.5 x 1.5 in (66 x 114 x 37.5 mm)
weight: 0.3 lbs (140 g)
IP code: 67
Operating temperature: -4 to +130 °F (-20 to +55 °C )
The RRC1 radio remote control allows users to control the pump.
Each RRC1 radio remote control is only paired to and should only be
used with the pump which it was supplied with. It is particularly suit-
able to utility cable cutting operations in limited access locations, eg.
in manholes, to enable working from a safe distance. Ergonomically
designed with a comfortable grip even while wearing work gloves.
The functions listed below are operable via the RRC1:
Function:
1- ON/OFF BUTTON: to switch on or off the
radio remote control. The radio remote control
automatically switches off after 3 minutes of
inactivity.
2- PUMPBUTTON:tostartthepump motor
or toreset anyalarms when pressed and
held for 2 seconds.
3- RELEASE BUTTON: can be operated at
any time (other than if there is an error)
to release the pressure allowing oil to be
returned to the pump reservoir.
4- INDICATOR LED: the center LED flashes
whentheradiocontrolisON(green when
the remote control battery is good, red
when the remote control battery is low).
5- HOOK: to hang the radio control to the rings (2)
of the pump or to the operator's belt during transportation or storage.
6- CLIP: to hang the radio control to the operator's belt.
7- POWER SWITCH: located on the back of the radio control, this switch stops the power supply
from the batteries. When in the off position (O), the radio control cannot be started.
When the radio remote control is transported by airplane, the on/off switch must be in the off
position. The switch should not be used as an on/off button for the radio control.
RRC1
RADIO REMOTE CONTROL
PUMP RELEASE
ON/OFF

14
Changing RRC1 batteries:
When approximately 10% of battery capacity remains, the top LED lights red.
- Remove the back of the radio control by unscrewing the 5 screws.
- Replace the 2 x 1.5V AAA batteries with the correct polarity.
Use alkaline batteries for optimal performance.
- Screw the back of the radio control into place.
BATTERY PRECAUTIONS
As batteries contain flammable substances such as lithium or other organic
solvents, they may cause heating, rupture or ignition.
WARNING! Do not recharge the batteries. Attempts to recharge may cause rupture or hazard-
ous liquids to leak, which will corrode the equipment.
NOTE: Electronics and batteries must be physically separated before disposal.
Make sure that electronics or batteries are not disposed of in household waste.
- There is a risk of explosion if a battery is replaced with the incorrect type of battery.
- Do not short circuit, disassemble, deform or heat batteries.
- Keep batteries out of reach of children. If a child swallows a battery, seek immediate medical
attention.
- When discarding batteries, insulate the + and - terminals of batteries with insulating/mask-
ing tape. Do not put multiple batteries into the same plastic bag.
- When improperly disposed, batteries may short circuit, causing them to become hot, burst
or ignite.
- Store in a cool place. Keep batteries away from direct sunlight, high temperatures, and high
humidity. Do not throw batteries onto fire.
3. INSULATED FLEXIBLE HOSE
High pressure flexible hoses are subject to a natural ageing process which can result
in a reduction in performance potentially affecting safety of the operator. As a result
their life span is limited. In order to ensure safe use of their units, Cembre recommends
replacing the hose within 10 years from the date printed on the fittings.
- Before using the pump always check the integrity of the flexible hose and the quick
couplers making sure there are no abrasions, cuts, deformations or swellings.
- Keep the flexible hose away from naked flames and sources of heat above 158°F (70°C).
- The factory fitted guards must be in place at each end of the flexible hose.
- Do not touch the flexible hose when under pressure.
- When using the pump, the flexible hose must be uncoiled and laid out straight.
The standard flexible hose is 33 ft (10 m) long. It is used to deliver oil under pressure, generated
by the pump, to the cutting head and as an insulating element between the head and the pump.
The insulated flexible hose is completely filled with an insulating oil with dielectric properties
which insulate the pump from the cutting head.
The working range of the cutting head is 33 ft from the pump; this distance allows the
proper communication between the head and the pump.
In case longer insulated flexible hoses are used and the pump is kept outside of the
manhole, it is possible that the wireless blade travel sensor signal will not reach the pump.
2
1
3
7
6
5
4
FRONT BACK
+
+
-
-
RRC1
RADIO REMOTE CONTROL
PUMP RELEASE
ON/OFF
ON/OFF

15
4. HYDRAULIC SAFETY CUTTING HEADS WITH BLADE TRAVEL SENSOR
TC085Y-KV-RC2 TC096Y-KV-RC2 TC120Y-KV-RC2
Max. cutting cable diameter
inch (mm)
3-3/8” (85) 3-3/4” (95) 4-3/4” (120)
Max. operating pressure
psi (bar) 10,000 (700)
Oil necessary (displacement)
cu. in. (cm3)5.5 (90) 7.6 (124) 11.1 (182)
Wireless sensor frequency
Mhz 915
Weight
lbs (kg) 13.4 (6.1) 21 (9.6) 23.7 (10.8)
Dimensions
inch
(mm)
16.1 x 5.9 x 9.2
(410 x 152x 233)
19.7 x 9.5 x 5.7
(500 x 242 x 145)
21.1 x 7.2 x 5.5
(536 x 184 x 139)
- Hydraulic cutting heads type -RC2 are fitted with a unique wireless blade travel sensor paired
to the receiver integrated in the pump.
- Each cutting head is uniquely paired to its specific pump using USA frequencies (915 MHz).
- The wireless sensor mounted on the head is maintenance-free as it is fully protected and has
battery-free technology.
- Select the appropriate cutting head for the diameter of the cable to be cut and use only with
the associated paired pump.
- The cutting heads must be positioned manually around the cable to be cut, they are fitted with
eyelets to hang the head for better support during operation.
- A grounding point is provided to facilitate grounding of the cutting head when required.
Cutting head description (Ref. to Fig. 3):
1 - MALE INSULATED QUICK COUPLER 5 - BLADE
2 - EYELETS FOR HANGING THE SUPPORT STRAP 6 - GROUNDING SOCKET + KNOB
3 - HANDLE (TC085..to be attached) 7 - CASE FOR WIRELESS BLADE SENSOR
4 - HEAD LATCH 8 - HEAD FIXING PIN
IMPORTANT Before using
the equipment, carefully
read all the warnings and
instructionsinthismanual.
Failure to follow the war-
ningsandinstructionsmay
result in electric shock,
fire and/or serious injury.
Keephandsclear
of cutting bla-
des.
WARNING LABELS
TG.0932
TG.0932
Always wear safety
gloves when ope-
rating these safety
cutting heads.
Do not cut Steel.
Do not attempt to cut
Steel ropes or Steel rein-
forced cables (ACSR),
the heads are designed
for cutting Copper or
Aluminum cable.
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(
(

16
4.1) Preparation
Only remove the cutting head from its case at the work place.
TC085Y-KV-RC2: mount the support handle (3) on the head
byscrewingitontothethreadedpin(14); whenfinishedusing
theunit,removethehandlebeforestoringtheheadinitscase.
4.2) Grounding the cutting head
To ground the cutting head, proceed as follows:
Using a grounding wire with lug termination
Unscrew knob (6) from the grounding socket (16) of the head (Ref. to Fig. 8).
Connect the terminal of the grounding wire to the socket using the knob (6), fasten the knob
tightly.
Fully unwind the grounding wire and connect the other end to the grounding system using
the clamp.
Using a grounding wire with ball & socket termination
Unscrew knob (6) from the grounding socket (16) of
the head.
Screw the grounding pin (15) tightly into the
socket (1/2”-13 UNC thread).
Fully unwind the grounding wire and connect one
end to the grounding pin (15) using the clamps and
the other end to the grounding system.
4.3) Positioning the cutting head around the cable
The appropriate cutting head should be chosen based on the size of the cable to be cut.
The cutting head must then be manually positioned around the cable.
TC096Y-KV-RC2: insert the cable between the blades.
TC085Y-KV-RC2: release latch (4) to open the blades.
insert the cable, close the head and fully secure the latch (4) (Ref. to Fig. 9).
Ensure that the head is fully secured: partial closure may damage the head.
TC120Y-KV-RC2: extract the locking pin (8) to open the blades.
Insert the cable, close the head and fully secure the locking pin (8) (Ref. to Fig. 10).
Ensure that the head is fully secured: partial closure may damage the head.
Make sure the blades are positioned exactly on the desired cutting point.
Once the blades of the cutting head are around the cable to be cut, stabilize the head to prevent
any movement during the cutting operation; when used within manholes we recommend the
usage of SS-TCY support strap (Ref. to section 4.4) in orderto support the head in a stable position.
15
16
14 3

17
4.4 SS-TCY support strap (purchase separately)
The support strap allows the cutting head to hang securely from a suitable support e.g when
cutting wall mounted cable inside manholes.
Connect the strap end hooks to the hanging eyelets (2) of the head (Ref. to Fig. 11).
Securely wrap the strap around a stable support above the head and latch it using the ring
(17).
Set the length of the strap by means of the buckle (16) support the head in a stable position.
5. INSTRUCTIONS FOR USE (Cutting operation)
STEP 1- Checking and testing the pump prior to cutting operations
Check all components (cutting head, flexible insulated hose, couplings and pump) before use to
verify there is no damage or leakage.
Checking and testing the unit prior to any cutting operations:
Check the battery charge and recharge it if necessary following the instructions in the battery
charger user manual. When a cutting operation begins, a check is made to determine whether
the battery charge is sufficient to complete the cutting operation. If this is not the case the
pump does not start. The LED (4) light will FLASH intermittently and the buzzer (5) will emit
an audible signal coordinated with the LED light.
Remove the battery from the pump (Ref. to Fig. 6).
Connect the flexible hose first to the cutting head and then to the pump (Ref. to Fig. 7).
Insert the battery into the pump.
Activate the pump by pressing forward the control button (11) on the pump,
the display lights up and the pump setting is displayed.
Turn on the radio control by pressing the ON/OFF button (1), the LED will
flash green, after 3 minutes the radio control automatically switches off.
Press the pump button (2) on the radio control to perform a test cutting operation.
During the operation the pump's LED light will FLASH intermittently and the buzzer will
emit an audible signal coordinated with the LED light.
Cutting operations must be strictly in accordance with the
safety and working procedures established by the respon-
sible power utility.
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........

18
At the end of the operation the pump will stop, the LED will remain a STEADY LIGHT (2 minutes)
and the speaker will emit a COUNTINUOUS BUZZER sound (30 seconds).This confirms the pump
received a signal from the cutting head acknowledging that the blades are
completely closed;
the display will show the following flashing screen
(Ref. to section 7.5 for further details).
Release the finger from the pump button (2) to initiate the SMART RELEASE function of the pump;
the operator should then check to ensure the blades are fully retracted to the start position.
Remove the battery from the pump.
Disconnect the flexible hose from the pump and cutting head.
At the end of the operation, in the event of a flashing LED light (2 minutes) and an
intermittent buzzer (30 seconds), this is to inform the operator that the wireless signal
to indicate the blades have fully traveled has not been received.
The display will show the following flashing screen (Ref. to section 7.6 for further
details).
STEP 2 – Bringing the cutting head down into the manhole
Secure the pump in proximity of the manhole or to the ladder, using the shoulder strap sup-
plied (Ref. to Fig. 4). The maximum distance between the cutting head and the pump is 33 ft
(10 m) assuming that the pump is positioned i n proximity of the manhole or on the ladder
under the street level.
Do not place the pump on dirty surfaces or in the presence of water.
Lower the cutting head and the flexible hose into the manhole.
Position the blades of the cutting head perpendicularly around the cable that has been identi-
fied for the cut, as described in section 4.3.
Stabilize the cutting head position and support the head by strapping it to the above wires or
cable holders. It is possible to hook the cutting head with the SS-TCY strap hooked to the hang-
ing points of the head (Ref. to Fig. 11) .
Connect one end of the grounding wire to the cutting head and the other end to the relevant
grounding attachment (Ref. to section 4.2).
Connect the flexible hose to the cutting head (Ref. to Fig. 7),
the operator should now leave the manhole.
After all personnel have exited the manhole or cable space, con-
nect the flexible hose to the pump (Ref. to Fig. 7).
Insert the battery.
Wake up the pump by pressing forward the control button (11)
(display ON).
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........
11

19
STEP 3 – Cutting operation
A protected zone must be established around the work place where entry is forbidden.
Switch on the radio control by pressing the start ON/OFF button (1), the LED will flash green.
In proximity of the manhole, at a safe distance, push the pump button (2) on the radio control
to start the cutting operation (Ref. to Fig. 4). The maximum distance between radio control
and pump is 66 ft (20 m) if within line of sight.
During the cutting operation the pump's LED light will flash intermittently and the
buzzer emits an audible signal coordinated with the LED light.
In the event that the buzzer is not heard, hold the pump button (2) for 1 minute,
after 1 minute the pump button can be released to start the automatic release of the cutting
blades.
STEP 4 – Checking the unit after the cutting operation
Look the pump and assess which of the following two situations has occurred:
1) THE CABLE HAS BEEN FULLY CUT
The STEADY LED LIGHT and the CONTINUOUS BUZZER confirm that the
blades have completed their full travel. The display will show the screen
alongside.
Access the area and remove the cutting head.
In case the blades are jammed after the cut, you can activate the FORCED RELEASE
MODE by pressing the release button 3 times within 2 seconds; refer to section 7.3.1
for further details.
2) THERE IS NO CERTAINTY THAT THE CABLE HAS BEEN FULLY CUT
A FLASHING LED LIGHT (2 MIN) and the INTERMITTENT BUZZER (30 seconds)
informstheoperatorthattheblade travelsensorsignal has notbeenreceived,
the display will show the following flashing screen.
In order to reset the alarm, hold the pump button for 2 seconds then repeat the cutting cycle.
Before approaching the cutting area to check the problem, strictly follow the safety
and working procedures established by the responsible power utility.
WARNING: In case of accidentally cutting live cable, strictly follow the working proce-
dures established by the responsible power utility.
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........

20
6. INSTRUCTIONS FOR USE (Crimping operation)
The pump is suitable for use with Cembre KV type protected crimping heads.
The default settings of the pump are:
- Operating mode: CUTTING (Ref. to section 7.2 to choose CRIMPING operating mode).
- Oil release mode: SMART (Ref. to section 7.3 for further details).
- Pump control mode: RADIO ON, operated by radio remote control only (Ref. to section 7.4 for
further details).
For a crimping operation select the crimping mode via the display, before starting any
crimping operations.
When the crimping mode is active, the LED light (4) and the buzzer (5) are deactivated.
When the battery is removed from the pump or after 1hour of inactivity (display OFF),
once you wake the pump up, it will always start with the default setting:
CUTTING MODE, SMART RELEASE and RADIO ON.
Connect the flexible hose, first to the head and then to the pump.
Press the control button (11) on the pump once to activate the pump, display ON.
Switch on the radio control by pressing the ON/OFF button (1).
Press the pump button (2), this activates the motor of the pump that feeds the
hydraulic head connected to it, pressurizing the oil.
Once the set pressure (Pn) is reached the pump will be switched off au-
tomatically, the display will briefly show the maximum pressure reached
(Pp) followed by “OK” to confirm the correct operation.
Releasing the pump button before the automatic stopping of the motor will
cause the pump to stop, keeping the oil pressure stable (Pp) at its current
pressure level. To complete the operation press the pump button
once more until the motor stops automatically.
At the end of the cycle, releasing the pump button will start the automatic
release of the ram and will allow return of the oil to the oil reservoir in the
pump (Ref. to section 7.3 for further details).
The display "ERROR" combined with 3 beeps and the LED flashing,
indicates an incorrect crimping procedure; the oil return phase oc-
curred too early without waiting for the motor to be automatically
switched off and therefore the minimum set pressure was not reached.
Repeat the crimping cycle by holding down the start button until the motor is automatically
switched off.
When a crimping head is used, always press and hold the pump button until the motor stops
automatically.
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........
Pp = 325 bar
RESET
SW:S1J41405
LED
OFF
ERROR
001
30001

BATTERY 





Pn= 729 bar


002


003


BATTERY
 
004


LED
ON
LED
OFF
LED
ON
max.
BATTERY BATTERY


min.
B68RC
NR 17AW125
10
29990

BATTERY
max 90°
90°
OK
Pn= 729 bar
Pp = 731 bar
RC ON
RESET
SW:S1J76202
Pn= 729 bar
P= 0 bar
P = 0 bar
Pn= 10573 psi
LED
ON
LED
OFF
max 90°
60°
* 1
* 2
3
4
5
* 6
* 7
* 8
* 9
10
P = 0 psi
P = 0 bar
Pn= 729 bar
P= 0 bar
BEEP

BEEP

RC OFF
Pn= 729 bar
OK
OK
SAVE 60%
100


P = 0 psi
P = .... bar
Pn= 729 bar
OK
Pn= 729 bar
Pp = 731 bar
Pn= 729 bar
P= 0 bar
58
01
59
60
.........