NICOPRESS 5612M User manual

MODEL 5612M
Battery Powered Compression Tool
INSTRUCTION NO. 5612M
THE NATIONAL TELEPHONE SUPPLY COMPANY
2307

Instruction No. 5612M Page 2of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
TABLE OF CONTENTS
I. SAFETY AND WARNING REMINDERS ....................................................................... 2
II. SPECIFICATIONS AND FEATURES.............................................................................. 5
III. ACCESSORIES.................................................................................................................. 5
IV. OPERATING INSTRUCTIONS........................................................................................ 6
V. PROPER CRIMPING……………………………………………………………………..6
______________________________________________________________________________
I. SAFETY AND WARNING REMINDERS
NOTE: The Nicopress®battery operated compression tool is designed to be used with Nicopress®
sleeves. Splicing any other items should not be attempted, as it may cause damage to equipment
and/or injury to personnel.
1) Carefully read, understand and follow all instructions in this manual and on the tool before
attempting to operate the equipment.
2) At all times wear safety eye protection.
3) Keep fingers out of pinch areas during operation.
4) Always point the tool away from other people.
5) If the tool is stored for an extended period at a temperature of less than 25ºF (-5ºC), the tool
should be allowed to return to room temperature to ensure smooth operation. Use the tool
only after it has been at room temperature for 1 hour.
6) Do not drop the tool. Dropping the tool may damage the hydraulic circuit and result in the
tool not functioning correctly.
7) Keep the head and ram clean and free of debris. Solvents can be used to clean the head but
should not be used on the plastic body. Use soap and water to clean the body.
PRECAUTIONS FOR THEBL1850B BATTERY
1) Do not short circuit the contacts or expose the cartridge to water, oil, or solvents.
2) Do not disassemble or attempt to repair the battery cartridge or dispose of in a fire.
3) Do not drop or otherwise abuse the battery cartridge.
4) Do not leave the cartridge in locations where it will be exposed to a temperature greater than 140ºF
(60ºC) for an extended period.
5) For long term storage beyond 2 months, it is recommended the battery cartridge be stored without
being recharged and should only be recharged closer to the time of use.
PRECAUTIONS FOR THE DC18RC CHARGER
1) This charger is for charging battery cartridge BL1850B only. Do not use the charger for any
other devices.
2) Allow battery cartridges to cool before charging.
3) Charge batteries at an ambient temperature of 50º to 95ºF (10º to 35º C). Charging time is
approximately 50 to 60 minutes for the BL1850B.
4) Never short circuit the output terminals.
5) Do not expose the charger to water, oil, or solvents.
6) Do not disassemble, attempt to modify, drop, or otherwise abuse charger.

Instruction No. 5612M Page 3of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
SAFETY SYMBOLS
You will see this symbol Exclamation Triangle throughout this manual. The purpose of this symbol
is to call your attention to the hazards and/or unsafe practices that have the potential to cause injury or
property damage. The severity of each hazard is further explained in detail below. Failure to follow all
instructions may result in electric shock, fire and/or serious injury. The term “power tool” in all
warnings refers to your battery operated (cordless) power tool.

Instruction No. 5612M Page 4of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
WORK AREA SAFETY
•Keep work area clean and well lit. Cluttered or dark areas invite accidents.
•Do not operate power tools in explosive atmospheres, such as in the presence of flammable
liquids, gases, or dust. Power tools create sparks which may ignite the dust or fumes.
•Keep bystanders away while operating a power tool. Distractions can cause you to lose control.
PERSONAL SAFETY
•Stay alert, watch what you are doing and use common sense when operating a power tool. Do not
use a power tool while you are tired or under the influence of drugs, alcohol, or medication. A
moment of distraction while operating power tools may result in personal injury.
•Use personal protection equipment. Always wear eye protection. Safety equipment such as dust
mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will
reduce personal injuries.
•Do not overreach. At all times keep proper footing and balance. This enables better control of the
power tool in unexpected situations.
TOOL USE AND CARE
•To prevent leakage, overheating, smoke generation, fire, and rupturing from occurring, follow
these instructions when handling our rechargeable power tools (tool main body/battery
pack/charger).
•Do not force the tool. Use the correct tool for your application. The correct tool will do the job
better and safer at the rate for which it was designed.
•Do not use the tool if the switch does not turn it on and off. Any tool that cannot be controlled
with the switch is dangerous and must be repaired.
•Disconnect the battery pack from the tool before making any adjustments, changing accessories,
or storing. Such preventive safety measures reduce the risk of starting the tool accidentally.
•Store idle tools out of the reach of children and do not allow persons unfamiliar with the tool or
these instructions to operate it. These tools can be dangerous in the hands of untrained users.
•Maintain tools. Check for misalignment or binding of moving parts, breakage of parts and any
other condition that may affect its operation. If damaged, have the tool repaired before use.
•Use power tools only with specifically designated battery packs. Use of any other battery packs
may create a risk of injury and fire.
•Under abusive conditions, liquid may be ejected from battery; avoid contact. If contact
accidentally occurs, flush with water. If liquid contacts eyes, seek medical help. Liquid ejected
from the battery may cause irritation or burns.

Instruction No. 5612M Page 5of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
II. SPECIFICATIONS
1) Output force –12 tons
2) Weight –15.5 lbs. (7kg) w/battery
3) Dimensions –16”L x 11.5”H x 3.6”W (406mm x 292mm x 91.44mm)
4) Wire rope sizes –3/64” to 1/2” (1mm to 13mm)
5) Approx. no. of crimps –110
FEATURES
1) One-hand operation
2) Optimized hydraulics offer 20% faster advance and 30% quicker retraction
3) Selectable auto-retract switch
4) 180-degree rotating head with forged jaws and protective brush guards
5) Fully enclosed weather resistant housing
6) Wrist strap
7) LED work lights
8) Ballistic nylon heavy duffle bag
III. ACCESSORIES
BATTERY CARTRIDGE
BL1850B
Battery Cartridge (BL1850B)
(two included with tool)
Battery type: Lithium Ion
Voltage: 18V DC
Rated current: 5.0 Ah
Charge time: 50 to 60 mins.
BATTERY CHARGER
DC18RC
Battery Charger (DC18RC)
(one included with tool)
Input voltage: 120 VAC single phase

Instruction No. 5612M Page 6of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
IV. OPERATING INSTRUCTIONS
PRE-USE CHECKLIST
1) Visually confirm there are no missing or broken components. If found, stop use and have the
tool checked by a qualified technician.
2) Check and ensure triggers are moving freely with no binding.
3) Rotate head where applicable to ensure it rotates 180 degrees. If head rotates more than that,
stop use and have tool checked by a qualified technician.
4) Please read instructions supplied with the battery and charger.
TRIGGER AND RELEASE BUTTON
1) The compression jaws close when the trigger is pressed and stops when the trigger is released.
2) To open the tool’s jaws, push the release button. The jaws continue to open while the release
button is pressed.
V. PROPER CRIMPING
1) Select the appropriate compression die set for the connector and cable being used. All
Nicopress®Series 6 Dies can be used with this tool.
2) Slide each die into place. Be sure both die halves are secure before operating the tool.
3) Place the connector between the die halves. Press the trigger and advance the ram so that the
connector is held between the die halves and insert the cable into the sleeve.
4) Press the trigger until the compression is completed. The ram will advance and once the cycle is
complete, the tool will automatically shut off. A green LED will appear on the display followed
by an audible beep to alert the user the compression was completed. If the cycle was not
completed, the LED will flash red and a series of audible beeps will sound, alerting the user the
cycle was not completed. If the dies fail to close, it will be due to:
•The tool being used for some application for which it was not designed
•The pressure not building up because of a depleted battery
•The dies being the incorrect size
5) Press the release button to retract the ram. The ram continues to retract while the release button is
pressed and stops when it reaches the lower end. Check the compression with the gauge.
USE OF CRIMP GAUGE
When using the gauge, it should be held so that it contacts the compressed portion of the sleeve at right
angles to the fins (flash). The compressed portion of the splice should enter the gauge easily.

Instruction No. 5612M Page 7of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
WIRE ROPE SPLICING
Because of many variations in wire and fiber rope design and construction, it is recommended that all
wire rope assemblies be pull tested prior to use.
It has been determined through pull testing that an eye splice using Nicopress®copper, copper plated
and stainless steel oval sleeves will hold military specification aircraft cable to its breaking strength,
when the cable is made to military specifications MIL-DTW-83420M,dated 12-06-2007 for cable
constructions 3x7, 7x7, 7x19 and Federal Specification RR-W-410F dated Nicopress®sleeves crimped
with Nicopress®tools.
Splices in wire rope are made by compressing two wires together inside a sleeve. To compress the
sleeve properly, position the sleeve between the crimping dies with the long axis of the sleeve aligned
with the crimping action of the dies.
LAP SPLICES
When the ends of two pieces of wire rope or both ends of the same rope are spliced together, this splice
is called a lap splice. Usually two sleeves are needed to develop a splice equal to the breaking strength
of the wire.
To make a proper lap splice, pull the ends of the rope trough both sleeves. Be sure to leave a space
between the sleeves to allow for extrusion of the sleeves during crimping and approximately 1/16” to
1/8” space between sleeves after crimping. The sleeve length, after crimping, can be found in
Nicopress® Catalog No. 4 for Oval Sleeves. The ends of the wire should extend approximately 1/16”
beyond the edge of the crimped sleeves.
EYE SPLICES
Eye splices are formed by pulling one end of the wire or fiber rope through the oval sleeve and looping
it back to form an eye (Figure 1). Line up the sleeve between the crimping dies with the long axis
perpendicular to the crimping action of the dies. The splice is made by the two wires being compressed
together inside the sleeve.
Figure 1

Instruction No. 5612M Page 8of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
Because of the many different types of wire rope, there can be no formula governing the exact size of
loop to use. It is suggested that the length of the loop be approximately twice the width (Figure 2).
Figure 2
All wire rope assemblies should be pull tested prior to use to ensure proper tensile strength.
COMPRESSION DIE CHART FOR WIRE ROPE SPLICING
Oval sleeves
Cable Size
Oval Sleeve
Stock #
Compression Die/
# of Presses Required
Cable Size
Oval Sleeve
Stock #
Compression Die/
# of Presses Required
3/64
18-11-B4
28-11-B4
428-1.5-VB4
168-1.5-VB4
188-1.5-VB4
12-OVAL-B4 (1)
12-OVAL-B4 (1)
12-OVAL-B4 (1)
12-OVAL-B4 (1)
12-OVAL-B4 (1)
7/32
18-8-F2
28-8-F2
428-7-F2
12-OVAL-F2 (2)
12-OVAL-F2 (2)
12-OVAL-F2 (2)
1/16
18-1-C
28-1-C
428-2-VC
168-2-VB4
188-2-VC
12-OVAL-C (1)
12-OVAL-C (1)
12-OVAL-C (1)
12-OVAL-B4 (1)
12-OVAL-C (1)
1/ 4
18-10-F6
28-10-F6
428-8-VF6
168-8-VF2
188-8-VF6
12-OVAL-F6 (2)
12-OVAL-F6 (2)
12-OVAL-F6 (2)
12-OVAL-F2 (2 ovlp)
12-188-VF6 (2)
3/32
18-2-G
28-2-G
428-3-VG
168-3-VC
188-3-VG
12-OVAL-G (1)
12-OVAL-G (1)
12-OVAL-G (1)
12-OVAL-C (1)
12-188-VG (1)
5/16
18-13-G9
28-13-G9
428-10-VG9
188-10-VG92
12-OVAL-G9 (3)
12-OVAL-G9 (3)
12-OVAL-G9 (3)
12-VG92 (4)
1/ 8
18-3-M
28-3-M
428-4-M
168-4-VG
188-4-VM
12-OVAL-M (1)
12-OVAL-M (1)
12-OVAL-M (1)
12-OVAL-G (1)
12-188-VM (1)
3/ 8
18-23-H5
28-23-H5
428-12-VH5
188-12-VJ8
12-OVAL-H5 (4)
12-OVAL-H5 (4)
12-OVAL-H5 (4)
12-OVAL-J8 (5)
5/32
18-4-P
28-4-P
428-5-VP
168-5-VM
188-5-VP
12-OVAL-P (2)
12-OVAL-P (2)
12-OVAL-P (2)
12-OVAL-M (1)
12-188-VP (2)
7/16
18-24-J8
28-24-J8
428-14-VJ8
188-14-VK8
12-OVAL-J8 (5)
12-OVAL-J8 (5)
12-OVAL-J8 (5)
12-OVAL-K8 (6)
3/16
18-6-X
28-6-X
428-6-VX
168-6-VP
188-6-VX
12-OVAL-X (2)
12-OVAL-X (2)
12-OVAL-X (2)
12-OVAL-P (3)
12-188-VX (2)
1/ 2
18-25-K8
28-25-K8
428-16-VK8
188-16-VM1
12-OVAL-K8 (6)
12-OVAL-K8 (6)
12-OVAL-K8 (6)
12-188-VM1 (4)

Instruction No. 5612M Page 9of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
Stop sleeves
Cable Size
Stop Sleeve Stock #
Compression Die/# of Presses Required
3/64
871-12-B4
12-OVAL-B4 (1)
1/16
871-1-C
878-2-VC
871-1-Q*
12-OVAL-C (1)
12-OVAL-C (1)
12-1-Q (1)
3/32
871-17-J
871-3-Q*
878-3-J
12-J (1)
12-1-Q (1)
12-J (1)
1/ 8
871-18-J
878-4-J
12-J (1)
12-J (1)
5/32
871-19-M
878-5-M
12-1M (1)
12-1M (1)
3/16
871-20-M
878-6-M
12-1M (1)
12-1M (1)
7/32
871-22-M
12-1M (1)
1/ 4
871-23-F6
878-8-VF6
12-OVAL-F6 (2)
12-OVAL-F6 (2)
5/16
871-26-F6
878-10-VF6
12-OVAL-F6 (2)
12-OVAL-F6 (2)
3/ 8
871-27-F6
12-OVAL-F6 (2)
COMPRESSION DIE CHART FOR SYNTHETIC & FIBER ROPE SPLICING
Oval sleeves
Cable Size
Oval Sleeve
Stock #
Compression Die/
/# of Presses Required
Cable Size
Oval Sleeve
Stock #
Compression Die/
# of Presses Required
1/16
1700-C
12-OVAL-C (1)
5/16
1700-G3
12-1700-G3 (4 ovlp)
1/ 8
1700-M
12-1700-M (1)
3/ 8
1700-H5
12-1700-H5 (4)
3/16
1582-P
12-1582-P (1)
1/ 2
1700-J8
12-1700-J8 (6)
1/ 4
1700-X
12-1700-X (2)

Instruction No. 5612M Page 10 of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
SOLUTION
Motor runs, but the
tool jaws will not
advance
Insufficient hydraulic oil
Consult factory for repair service
Air block in hydraulic system
Invert tool to allow air to rise towards the
top of the oil bladder
Defective hydraulic circuit
Consult factory for repair service
Motor runs, tool
jaws advance but
will not build
pressure
Insufficient hydraulic oil
Consult factory for repair service
Defective suction valve or
bypass cartridge
Consult factory for repair service
Motor will not run
at all
Defective battery
Charge or replace battery
Bad contact or loose battery
connections
Check all connections and wires
Misaligned switch
Check to make sure that switch is
properly aligned with trigger
Consult factory for repair service
Tool blades will
not release
Tool did not complete a full
cycle and bypass
Press trigger and allow tool to bypass
Small wire stuck between
blades
Gently utilize hammer and wood block
Release trigger is bent or
misaligned
Consult factory for repair service

Instruction No. 5612M Page 11 of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
MODEL 5612M WARRANTY
The 5612M battery tool has a 1-year warranty and the BL1850B battery and charger has a 3-year
warranty. The warranty does not cover any damages incurred from a Nicopress®tool including damages
to property, bodily injury and lost wages resulting from such injuries. This warranty solely covers the
repair or replacement of tools supplied by Nicopress®. These remedies are exclusive, and the total
liability of Nicopress®, whether based on contract, warranty negligence, indemnification, strict liability
or otherwise, shall not exceed the purchase price of the tool. In no event shall Nicopress®be liable for
consequential, incidental, or special damages.
Nicopress®makes no other warranties of any kind, expressed or implied, and all implied warranty,
including warranties of merchantability and fitness for a particular purpose are disclaimed.
Nicopress®reserves the right to determine all warranty claims. Nicopress®will not warranty tools
containing parts or batteries not originally supplied by Nicopress®. Failure due to misuse, improper
maintenance, misapplication, not following instructions or warnings, abuse or repairs attempted by
anyone other than Nicopress®render this warranty null and void.
HOW TO GET SERVICE UNDER THE TERMS OF THE LIMITED WARRANTY
Return your product directly to a Nicopress®Authorized Distributor
Call a Nicopress®Authorized Distributor stating the tool’s purchase date and problem description. You
will be given a Return Goods Authorization No. to assure that your merchandise will be handled
properly upon receipt. Non-warranty repairs are handled using the same procedure. Repairs exceeding
50% of the cost of a new tool will be advised before repairs are made.
CAUTION: Make sure the product is packaged adequately to prevent damage or loss during transit. The
shipment must be pre-paid and we recommend that it be insured. A cover letter indicating the reason for
the return should be included to facilitate repairs.
FACTORY MAINTENANCE RECONDITIONING SERVICE
A factory maintenance reconditioning service is available beyond the warranty period to accommodate
normal tool wear. Contact your Authorized Distributor for information and details.
PLEASE RETAIN FOR YOUR RECORDS
Purchaser’s Name
________________________________________________
Address
________________________________________________
City, State, Zip
________________________________________________
Tool Model Number
________________________________________________
Serial Number
________________________________________________
Date
________________________________________________
Purchased From
________________________________________________

Instruction No. 5612M Page 12 of 12
Nicopress®is a registered trademark of The National Telephone Supply Co. www.nicopress.com
SEND THIS PORTION WITH ANY TOOL WHEN REQUESTING
REPAIRS, WARRANTY OR RECONDITIONING WORK
PLEASE CALL, EMAIL OR FAX A NICOPRESS®AUTHORIZED DISTRIBUTOR
Nicopress RGA No.___________________________________
Distributor__________________________________________
Address_____________________________________________
City___________________________________ State_____ Zip________
Tool Model_________________________
Serial No___________________________
Warranty Claim_____ Repair Only____ Estimate Required: Yes____ No____
Problem Description_______________________________________________
_________________________________________________________________
Customer Name__________________________
Phone (______)_________________________
Address______________________________________________
City___________________________________ State_____ Zip________