JST BCT-8150 User manual

The Quality Connection
BCT-8150
HYDRAULIC CRIMPER
Instruction Manual

2 The Quality Connection
Table of Contents
1. Introduction………………………………………………………………………. 3
2. Specifications……………………………………………………………………. 3
3. Features………………………………………………………………………….. 4
4. Name of Components……..……………………………………………………. 4
5. Estimated Crimping Cycles…………………………………………………….. 4
6. Operation…………………………………………………………………………. 5
7. Precautions……..…………………………………………………………………9
8. Maintenance………………………………………………………………………10
9. Troubleshooting……….………………………………………………………… 11

3 The Quality Connection
1. Introduction
The BCT-8150 is a battery operated 12 ton hydraulic crimping tool. Mechanism of this
tool is very simple. Manual pumping is replaced by a reciprocating motion driven by DC
motor using cam action.
2. Specifications
Crimping Tool BCT-8150
Output: 12 tons
Applicable range: Nominal size 8~150
Motor: 14.4V DC
Dimensions: 370 L x270 H x90 W
Weight: 5.2kg(11.44lbs)
Battery Cartridge BP-70MH
Type of Battery: NI-CD enclosed cylinder type
Output: DC14.4 V
Capacity: 1.2AH
Charging Time: 1 hour
Dimensions: 100 L x137 H x70 W
Weight: 0.73kg(1.61lbs)
Battery Charger CH-35R
Input: 120VAC 60hz
Charging Time: 1 hour
Dimensions: 195L x 95 H x 110 W
Weight: 1.9kg(4.18lbs)
Standard Accessories
Battery Pack: BP-70MH (2 cartridges)
Battery Charger: CH-35R
Dies: 8~150 nominal size
Carrying Case

4 The Quality Connection
3. Features
1. Automatic self contained power tool.
2. Removable battery cartridge. Change cartridge for continuous operation.
3. One hand operation. One hand controls ram advancement and retraction.
4. No physical effort required for crimping. No pumping action required.
4. Name of Components
LED Indicator
Battery Cartridge
Operation/Release Trigger
Slide Pin Fluid Fill Cap
Cylinder Head
5. Estimated Crimping Cycles
The average number of crimping cycles of a fully charged battery are listed below. Crimping
cycles may vary due to various charging conditions. Number of cycles below are
approximate and for reference only. When crimping cycles of a fully charged battery
cartridge approaches half of the cycles indicated below, the battery cartridge should be
replaced soon. Battery recharging can be repeated approximately 500 times before needing
to be replaced.
Nominal Size Crimps per Charge
8 110
14 90
22 70
38 70
60 50
70 50
80 50
100 40
150 30
When the LED indicator on the tool lights up the battery needs to be recharged. After the LED
indicator stays on the tool will only operate another 5~10 times depending on conductor size
and battery conditions. The indicator may light up momentarily when the trigger is press. This
is normal and should be disregarded. Charge the battery only when thee indicator stays on.

5 The Quality Connection
6. Operation
Charging
Cavity
1. Insert the AC plug of the battery charger into a wall outlet.
LED Indicator
CAUTION: MAKE SURE THE INPUT VOLTAGE IS 120VAC.
IF THE VOLTAGE SUPPLIED IS MORE THAN 130VAC THE
CHARGER AND THE BATTERY CARTRIDGE MAY BE
DAMAGED.
2. Insert the battery cartridge into the cavity of the charger.
CAUTION: KEEP THE CAVITY OF THE BATTERY CHARGER
FREE OF FOREIGN MATERIALS, ESPECIALLY METAL
OBJECTS.
Battery Cartridge
3. Time needed for a full recharge is 1 hour. The LED indicator
will be green when charging and turn orange when charging
is complete.
CAUTION: BE SURE TO FULLY RECHARGE THE BATTERY
WHEN THE TOOL IS DELIVERED OR AFTER A LONG TIME
OF STORAGE. IT IS RECOMMENDED TO FULLY
DISCHARGE THE BATTERY BEFORE RECHARGING.
Battery Cartridge
1. Depress the latch on the battery when detaching.
2. Slide the battery into the tool to install. Be sure the battery
is fully inserted and securely latches.
Latch

6 The Quality Connection
Selection of Proper Dies
Female Die Male Die
Applicable Nominal Applicable Female
Die Male Die
Terminals Size Wire Range
(mm sq.)
8 6.64~10.52
TD-221 TD-211
Non-insulated 14 10.52~16.78 TD-222 TD-211
Terminals and 22 16.78~26.66 TD-223 TD-212
Splices 38 26.66~42.42 TD-224 TD-212
(Butt type, 60 42.42~60.57 TD-225 TD-213
Parallel type) 70 60.57~76.28 TD-226 TD-213
80 76.28~96.3 TD-227 TD-214
100 96.3~117.2 TD-228 TD-214
150 117.2~152.05 TD-229 TD-215
Note: Applicable wire range for parallel type non-insulated slices denotes the
total cross sectional areas of the wires to be used.
1. Choose the correct terminal and wire combination.
2. Choose the correct male and female dies from the chart above to match the nominal size
terminal to be used. The dies are clearly marked with the die number.
CAUTION: SELECTING THE WRONG COMBINATION OF DIES COULD DAMAGE THE
DIES OR THE TOOL ITSELF.

7 The Quality Connection
Mounting dies
Slide Pin
1. Retract the piston by depressing the release trigger on
the main body of the tool.
Piston
2. Pull the slide pin out to open the crimp head.
3. With the crimp head open insert the female die until it is
locked into place by the ball plungers.
Female Die
4. Fully insert the male die into the piston.
Male Die
5. Close the crimp head and replace the slide pin.

8 The Quality Connection
Preparing Wire To Crimp
1. Strip the wire insulation per the specifications below.
Terminal
Butt-type splices
Parallel-type splices
Crimping
1. Insert the terminal into the female die with the brazed seem
facing the male die.
2. Depress the operation trigger and advance the piston until
the dies are holding the terminal.
3. Insert the conductor into the terminal.
4. Depress the operation trigger until the piston has fully
extended and crimping is complete. A clicking sound is heard
when crimping is complete.
5. Depress the release trigger to retract the piston. Hold it until
the piston has completely retracted.
6. Pull the slide pin out and open the crimp head to remove the
crimped terminal.

9 The Quality Connection
7. Precautions
Crimping Tool
1. Be sure to select the appropriate dies for the terminal to be crimped.
2. Never operate the tool without dies mounted and a terminal being crimped.
3. If the tool is stored at a cold temperature for an extended time, it is advisable to return to
room temperature for 1 hour before using.
4. Avoid dropping the tool. Excessive shock may damage the hydraulic circuit causing the
tool to malfunction.
5. Keep the cylinder head and piston clean and free of debris. Solvent can be used on the
head but should not be used on the plastic body.
Battery Cartridge
1. Never short circuit the battery terminals.
2. Avoid getting water, oil, or solvent near the battery.
3. Never disassemble or modify the battery.
4. Avoid dropping the battery cartridge.
5. Never store the battery at above 60 degrees Celsius for a long period of time.
6. Replace the battery cartridge when the crimping cycles are reduced to half of the cycles
indicated in the estimated crimping cycles section.
7. Never dispose of the battery cartridge in a fire.
8. The battery cartridge self discharges over time. It is recommended to charge the battery at
least every 3 months if the tool is not regularly used.

10 The Quality Connection
Battery Charger
1. Never use the charger to charge other appliances.
2. Charger should be operated at 10~35 degrees C (50~95 degrees F).
3. Normal charging time is 1 hour. When charging several batteries, wait 15 minutes between
charging.
4. Never short circuit the output terminals.
5. Avoid water, oil, or solvent.
6. Never disassemble or modify.
7. Avoid dropping.
8. Maintenance
1. Daily maintenance is important to keep the tool in good working condition.
2. When storing the tool, avoid humidity.
Oil Reservoir
3. If air is trapped in the hydraulic circuit the piston will not move
back and forth smoothly. To replenish the oil remove the reservoir
cap and fill. Be sure to remove the battery and stand the tool on end
as shown to prevent the oil from spilling. Be sure to use Shell Tellus
T15 or equivalent.
4. Change the hydraulic fluid every 24 months. Approximately 120cc
of fluid is needed. When changing the oil be sure not to let air or dust
get mixed in the oil.

11 The Quality Connection
9. Troubleshooting
The BCT-8150 consists of the following group of parts. In is important to identify which group
of parts have fails or are causing a problem.
1. Crimp Head
2. Hydraulic Body
3. Pump Piston
4. Reduction Gear
5. Motor
6. Circuit Board & Stitches
7. Battery
1. Crimp Head:
Generally the only types of problems that will be found in the crimp head will be wear,
fatigue, cracks, or terminal jamming.
2. Hydraulic Body:
The hydraulic body creates 10,000 PSI of oil pressure. This pressure is supplied to the
hydraulic cylinder which pushes the piston to create the required output. The hydraulic body
has four major key valves.
•Suction Valve: Ball seat sub assembly placed in the reservoir or ball seat in the body
which can be accessed from the reservoir side.
•Exhaust Valve: Ball seat assembly in the body ram side.
•Release Valve: Ball seat assembly with release pin in the body.
•Relief Valve: Pintal valve sub assembly either in the reservoir or in the body can be
accessed from outside the body.
3. Pump Piston:
Pump piston connects the hydraulic body and the reduction gear. It receives reciprocation
movement from the reduction gear. Pumping is done by this pump piston reciprocation just
like any other hydraulic tool.
4. Reduction Gear:
Reduction gear is driven by the motor and reduces the RPM to create sufficient force to
push the pump piston. All components are mechanical.
5. Motor:
14.4VDC motor is powered by a battery cartridge.
6. Circuit Board & Switches:
The circuit board senses the supplied voltage and if it is too low the LED lights up to signal
the battery has only enough charge for a few more crimp cycles.
7. Battery Cartridge:
Ni-Cd 14.4VDC battery.

12 The Quality Connection
Problem:
Motor does not run.
Possible Cause:
Motor, battery, and/or switches.
•Check connections for loose wires.
•Check if the battery is charged.
•Check that the trigger switch properly operates.
•Separate the motor from the reduction gear and see if it runs.
Problem:
Motor runs but the ram/piston does not advance.
Possible Cause:
Hydraulic body or reduction gear.
•Check the oil level in the reservoir.
•If air is trapped in the hydraulic circuit, depress the trigger for two seconds while
depressing the release button at the same time to circulate the oil. Then properly fill
the oil level.
•Separate the reduction gear from the hydraulic body. If the gear runs the problem is in
the hydraulic body.
In the event that the troubleshooting section did not help to solve the problem you will need
to contact the JST Service Engineering Department at [phone] for a return
authorization number and return the tool for repair.