TASKMASTER TB-6W0500-I User manual

Instruction manual
Model: TB-6W0500-I
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
TASKMASTER TOOLS
4730 Madison Road
Cincinnati OH 45227
www.ilsco.com
Phone:
800-776-9775
513-533-6200

2
TB-6W0500-I
Table of Contents
Warranty and Servicing......................................................................................................................................................3
Safety Symbols......................................................................................................................................................................3
Safety....................................................................................................................................................................................4-5
Identication..........................................................................................................................................................................6
Kit Includes.............................................................................................................................................................................7
Technical Specications.....................................................................................................................................................8
Identication of Battery Charger and Pack.................................................................................................................9
Battery Charger............................................................................................................................................................10-11
Battery Pack...................................................................................................................................................................12-13
Operating Instructions..............................................................................................................................................14-16
Tool Maintenance..............................................................................................................................................................17
Battery Status Lights.........................................................................................................................................................18
Maintenance Status Lights.............................................................................................................................................18
Software Installation.........................................................................................................................................................19
Tool Parts Breakdown.......................................................................................................................................................20
Parts List................................................................................................................................................................................21
Jaw Assembly Breakdown and Parts List
...................................................................................................................
22
Head Assembly Breakdwon and Parts List
................................................................................................................
23
Thank you...
for buying a TASKMASTER TOOL. Our mission is to bring product innovation and exceptional
customer service to the marketplace. This tool line is reliable, dependable, and durable for our
customer’s needs.
Please read this instruction manual carefully before using the product. If you have any questions
about our product please reach out to our customer service department (see back cover). No part
of the contents of this manual may be reproduced, transmitted or circulated in any form or by any
means without the prior written authorization of TASKMASTER TOOLS.

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TB-6W0500-I
SAFETY SYMBOLS
Do not dispose
of product.
Please recycle
Electric Shock
Hazard- use
proper protective
equipment
Attention!
Risk of
cutting injury
Read the operating
instructions
before use
Wear protective
goggles
Never use
without dies
WARRANTY AND SERVICING
TASKMASTER PRO 5-Year Tool Service Protection Program
Introducing the industry’s best service & support program for all your ILSCO battery-powered
crimping and cutting tools. All ILSCO battery-powered tool buyers are automatically registered in the
TASKMASTER PRO Service Protection Program and will receive free tool repairs for defects in material
or workmanship on their tool(s) for ve years after their original purchase date. (Excludes abuse,
non-intended use, tampered with or normal wear and tear.)
TASKMASTER PRO Tool 5-Day Repair Pledge
If your tool(s) need repair at any time within ve years of your original purchase date, our
TASKMASTER PRO service network will repair your registered tools within ve business days of
receipt.
TASKMASTER PRO Tool Loaner Program
If you need a replacement tool during any repair, our TASKMASTER PRO network can typically provide
a comparable loaner tool to registered tool owners while your tool is being repaired.
FREE Tool Reconditioning
Your rst reconditioning is on us! Call us after about 20,000 cycles.
To Find a TASKMASTER PRO Service Partner
Call ILSCO for assistance in solving tool performance issues or for any of your service needs. ILSCO
tool owners will be oered options to solve any tool replacement, parts or repair issues.
Call 513-533-6200 or 800-776-9775
Monday to Friday
8:00AM to 5:00PM Eastern Time (ET)
MILWAUKEE BATTERIES- LIMITED 3-YEAR WARRANTY
Every MILWAUKEE Battery Pack (sold with ILSCO Battery-Powered product and/or as a replacement
battery pack) is warranted to the original purchaser only to be free from defects in material and
workmanship. Subject to certain exceptions, MILWAUKEE will repair or replace a battery pack which,
after examination, is determined by MILWAUKEE to be defective in material or workmanship for
the stated warranty period from date of purchase. Return of the battery pack to a MILWAUKEE
factory Service Center location or MILWAUKEE Authorized Service Station, freight prepaid and
insured, is required. For the proper shipping procedure of battery packs, contact 1.800.SAWDUST
(1.800.729.3878), or go to www.milwaukeetool.com. A copy of the proof of purchase should
be included with the return product. This warranty does not apply to damage that MILWAUKEE
determines to be from repairs made or attempted by anyone other than MILWAUKEE authorized
personnel, misuse, alterations, abuse, normal wear and tear, lack of maintenance, or accidents.

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TB-6W0500-I
SAFETY
Read all safety warnings, instructions provided with this battery operated tool. Failure to
follow all instructions listed below may result in electric shock, re and/or serious injury.
Save all warnings and instructions for future reference.
WORK AREA SAFETY
• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• Do not operate battery operated tools in explosive atmospheres, such as in the
presence of ammable liquids, gases or dust. Battery operated tools create sparks
which may ignite the dust or fumes.
• Keep children and bystanders away while operating a battery operated tool.
Distractions can cause you to lose control.
PERSONAL SAFETY
• Stay alert, watch what you are doing and use common sense when operating a
battery operated tool. Do not use a battery operated tool while you are tired or under
the inuence of drugs, alcohol, or medication. A moment of inattention while using
battery operated tools may result in serious personal injury.
• Use personal protective equipment. Always wear eye protection. Protective
equipment such as rubber gloves, non-skid safety shoes, hard hat or hearing
protection used for appropriate conditions will reduce personal injuries.
• Do not overreach. Keep proper footing and balance at all times. This enables better
control of the battery operated tool in unexpected situations.
• Do not let familiarity gained from frequent use of battery operated tools allow you
to become complacent and ignore tool safety principles. A careless action can cause
severe injury within a fraction of a second.
BATTERY OPERATED TOOL USE AND CARE
• Do not force the battery operated 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.
• Remove the battery pack from the tool before making any adjustments, changing
accessories, or storing tools. Such preventive safety measures reduce the risk of
starting the battery operated tool accidentally.
• Store idle battery operated tools out of the reach of children and do not allow
persons unfamiliar with the tool or these instructions to operate the tool. Battery
operated tools are dangerous in the hands of untrained users.
• Maintain battery operated tools and accessories. Check for misalignment or binding
of moving parts, breakage of parts and any other condition that may aect the tool‘s
operation. If damaged, have the tool repaired before use. Many accidents are caused
by poorly maintained tools.

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TB-6W0500-I
• Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp
cutting edges are less likely to bind and are easier to control.
• Use the battery operated accessories in accordance with these instructions, taking
into account the working conditions and the work to be performed. Use of the tool
for operations dierent from those intended could result in a hazardous situation.
BATTERY USE AND CARE
• Recharge only with the charger specied by the manufacturer. A charger that is
suitable for one type of battery pack may create a risk of re when used with
another battery pack.
• When battery pack is not in use, keep it away from other metal objects, like paper
clips, coins, keys, nails, screws or other small metal objects, that can make a
connection from one terminal to another. Shorting the battery terminals together
may cause burns or a re.
• Under abusive conditions, liquid may be ejected from the battery; avoid contact.
If contact accidentally occurs, ush with water. If liquid contacts eyes, additionally
seek medical help. Liquid ejected from the battery may cause irritation or burns.
• Do not use a battery pack or tool that is damaged or modied. Damaged or
modied batteries may exhibit unpredictable behavior resulting in re, explosion or
risk of injury.
• Do not expose a battery pack or tool to re or excessive temperature. Exposure to
re or temperature above 265°F (130°C) may cause explosion.
• Follow all charging instructions and do not charge the battery pack outside the
temperature range specied in the instructions. Charging improperly or at
temperatures outside the specied range may damage the battery and increase the
risk of re.
SERVICE
• Have your battery operated tool serviced by a qualied repair person using only
identical replacement parts. This will ensure that the safety of the battery operated
tool is maintained.
• Never service damaged battery packs. Service of battery packs should only be
performed by the manufacturer or authorized service providers.

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TB-6W0500-I

Crimping Jaw
Head Release Lever
Release Button
USB Interface
Maintenance Status Light
Carrying Loop
Battery Pack
Battery Release Buttons
}Battery Status Light
Advance Trigger
Label
IDENTIFICATION







}


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TB-6W0500-I
KIT INCLUDES
1 Battery Powered Tool 2 Milwaukee Batteries
1 Milwaukee Charger 1 USB Cord
1 Shoulder Strap 1 Case

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TB-6W0500-I
TECHNICAL SPECIFICATIONS
Force developed: 6 tons
Battery voltage: 18 V
Battery capacity: 2.0 Ah
Type of battery: Lithium-ion
Charging time: 60 min (approx)
Hydraulic oil: Shell Tellus S2 V 15
Operating temperature range: -4° to 122° (F)
Dimensions: 20 in. x 3.1 in. x 5.2 in. (L x H x W)
Weight: 8.1 lbs. including battery
Connector Range
Lugs and Splices 500kcmil - #8 Cu
350 kcmil - #8 Al
H-Taps 4/0-4/0 Al Max
20 in (with head)
3.23 in (82 mm) 5.47 in (139 mm)
16.54 in (420 mm)

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TB-6W0500-I
IDENTIFICATION OF BATTERY CHARGER AND PACK
Charger Battery Pack








}
Light Indicators:
•Continuous red: Charging
• Slow flashing green: Approaching full charge
• Continuous green: Charging is complete
• Fast flashing red: Battery is too hot/cold- Charging will begin when
battery reaches correct charging temperature
• Slow flashing red: Battery charge is pending - Charging will begin
when the first pack is fully charged
• Flashing red/green: Damaged or faulty battery pack
Bays
Vents
Cord
Battery Contacts
Release Buttons
Fuel Gauge Button
Fuel Gauge
}Rapid Charge-Capable Pack Indicator

10
TB-6W0500-I
BATTERY CHARGER
Charge only MILWAUKEE M18™ Li-Ion batteries in this MILWAUKEE Li-Ion charger.
Other types of batteries may cause personal injury and damage.
WHEN TO CHARGE THE BATTERY PACK WITH THIS MILWAUKEE CHARGER
Remove the battery pack from the tool for charging when convenient for you and your job.
MILWAUKEE batteries do not develop a memory when charged after only a partial discharge. It is
not necessary to run down the battery pack before placing it on the charger.
• Use the Fuel Gauge to determine when to charge your MILWAUKEE Li-Ion battery pack.
• You can Top-O your battery pack‘s charge before starting a big job or long day of use.
• The only time it is necessary to charge the MILWAUKEE Li-Ion battery pack is when the battery
pack has reached the end of its charge. To signal the end of charge, power to the tool will drop
quickly, allowing you just enough power to nish making a crimp. Charge the battery pack as
needed.
HOW TO CHARGE THE BATTERY PACK
Align the battery pack with the bay and slide the battery pack into the charger as far as possible.
The red light will come on, either ashing quickly (battery pack is too hot or cold), ashing slowly
(battery pack is waiting for another pack to nish charging) or continuous (pack is charging).
• A fully discharged battery pack with an internal temperature in the normal range will charge
in about 30 to 185 minutes, depending on the battery pack.
• Heavily cycled batteries may take longer to charge completely.
• The Fuel Gauge lights on 18V battery packs are displayed as the pack is being charged,
indicating how fully charged the pack is. The fuel gauge will turn o when charging is
complete.
• After charging is complete, the continuous green light will come on.
• The charger will keep the battery pack fully charged if it is left on the charger. The light
indicator will ash green during this maintenance charging.
• The second pack inserted in the charger will begin charging when the rst pack inserted is
fully charged.
• If the light indicator ashes red and green, check that the battery pack is fully seated into the
bay. Remove the battery pack and reinsert. If the light continues to ash red and green,
remove pack(s) and unplug charger for at least 2 minutes. After 2 minutes, plug charger back
in and insert pack. If the problem persists, contact a MILWAUKEE service facility.
• If the light indicator does not come on, check that the battery pack is fully seated into the bay.
Remove the battery pack and reinsert. If the light indicator still does not come on, remove
pack(s) and unplug charger for at least 2 minutes. After 2 minutes, plug charger back in and
insert pack. If after these attempts the light indicator still does not come on, contact a
MILWAUKEE service facility.

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TB-6W0500-I
CHARGING A HOT OR COLD BATTERY PACK
The Red Flashing Indicator light on the charger indicates that the battery pack temperature is
outside the charging range. Once the battery pack is within the acceptable range, normal charging
will take place and the red light will be continuous. Hot or cold batteries may take longer to charge.
POWER THE CHARGER WITH AN INVERTER OR GENERATOR
The charger will operate with most generators and inverters rated at 350 Watts or higher.
MAINTENANCE AND STORAGE
Store your charger in a cool, dry place. As a general practice, it is best to unplug battery chargers
and remove batteries when not in use. No battery pack damage will occur, however, if the charger
and battery pack are left plugged in.
REPAIRS
The charger has no serviceable parts.
MOUNTING TO THE WALL
Use the wall mount guides to mark the hanging points.
To reduce the risk of injury, always unplug the charger and remove the battery from
the charger before performing any maintenance. Never disassemble the battery or charger.
Contact a MILWAUKEE service facility for ALL repairs.
To reduce the risk of injury and damage, never immerse your battery or charger in liquid or allow a
liquid to ow inside them.
CLEANING
Clean out dust and debris from charger vents and electrical contacts by blowing with compressed
air. Use only mild soap and a damp cloth to clean the battery pack and charger, keeping away from
all electrical contacts. Certain cleaning agents and solvents are harmful to plastics and other
insulated parts. Some of these include gasoline, turpentine, lacquer thinner, paint thinner,
chlorinated cleaning solvents, ammonia and household detergents containing ammonia. Never
use ammable or combustible solvents around batteries, charger, or tools.

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TB-6W0500-I
BATTERY PACK
FUEL GAUGE
Use the Fuel Gauge to determine the battery pack‘s remaining run time. Press the Fuel Gauge
button to display the lights. The Fuel Gauge will light up for 2-3 seconds. When less than 10% of
charge is left, 1 light on the fuel gauge will ash slowly.
NOTE: If the Fuel Gauge doesn‘t appear to be working, place the battery pack on the charger and
charge as needed.
Compared to NiCd battery pack types, MILWAUKEE Li-Ion battery packs deliver fade-free power
for their entire run time. The tool will not experience a slow, gradual loss of power as you work. To
signal the end of discharge, 1 light on the fuel gauge will ash quickly for 2-3 seconds and the tool
will not run. Charge the battery pack.
NOTE: Immediately after using the battery pack, the Fuel Gauge may display a lower charge than it
will if checked a few minutes later. The battery cells recover some of their charge after resting.
BATTERY PACK PROTECTION
To protect itself from damage and extend its life, the battery pack‘s intelligent circuit monitors
current draw and temperature. In extremely high torque, binding, stalling, and short circuit
situations, the battery pack will turn OFF the tool if the current draw becomes too high. All the fuel
gauge lights will ash. Release the trigger and restart. Under extreme circumstances, the internal
temperature of the battery could become too high. If this happens, the fuel gauge lights will ash
in an alternating pattern and the tool will not run. Allow the battery to cool down.

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TB-6W0500-I
COLD WEATHER OPERATION
MILWAUKEE Li-Ion battery packs are designed to operate in temperatures below freezing. When
the battery pack is too cold, it may need to warm up before normal use. Put the battery on a tool
and use the tool in a light application. It may buzz for a short time until it warms up. When the
buzzing stops, use the tool normally.
To reduce the risk of re, personal injury, and product damage due to a short circuit,
never immerse your tool, battery pack or charger in uid or allow a uid to ow inside them.
Corrosive or conductive uids, such as seawater, certain industrial chemicals, and bleach or bleach
containing products, etc., can cause a short circuit.
MAINTENANCE AND STORAGE
Do not expose your battery pack or cordless tools to water or rain, or allow them to get wet. This
could damage the tool and battery pack. Do not use oil or solvents to clean or lubricate your
battery pack. The plastic casing will become brittle and crack, causing a risk of injury. Store battery
packs at room temperature away from moisture. Do not store in damp locations where corrosion
of terminals may occur. As with other battery pack types, permanent capacity loss can result if the
pack is stored for long periods of time at high temperatures (over 120° F). MILWAUKEE Li-Ion
battery packs maintain their charge during storage longer than other battery pack types. After
about a year of storage, charge the pack as normal.
TRANSPORT
Personal transport of Li-Ion battery packs is allowed when done in accordance with these
warnings and instructions. The proper classication, packaging, labeling, marking, and
documentation requirements for shipping Li-Ion batteries is dependent upon whether the
particular batteries is dependent upon whether the particular batteries are rated greater than or
less than 100 Wh. Generally, Li-Ion batteries rated 100 Wh or less are excepted from certain Class
9 DG requirements. Always check compliance of Li-Ion battery consignments against the current
regulations governing the chosen mode of transport. When in doubt, contact the carrier or other
trained Dangerous Goods professional to conrm acceptability. Li-Ion packs are shipped under
classication UN 3480 (battery only) or UN 3481 (batteries contained in or packed with equipment).
To reduce the risk of injury or explosion, never burn or incinerate a battery pack
even if it is damaged, dead, or completely discharged. When burned, toxic fumes and materials are
created.
DISPOSING OF MILWAUKEE LI-ION BATTERY PACKS
MILWAUKEE Li-Ion battery packs are more environmentally friendly than some other types of
power tool battery packs (e.g., nickel-cadmium). Always dispose of your battery pack according to
federal, state, and local regulations. Contact a recycling agency in your area for recycling locations.
Even discharged battery packs contain some energy. Before disposing, use electrical tape to cover
the terminals to prevent the battery pack from shorting, which could cause a re or explosion.
RBRC BATTERY RECYCLING SEALS
The RBRC™ Battery Recycling Seals (see Symbology) on your tool battery packs indicate that
MILWAUKEE has arranged for the recycling of that battery pack with the Rechargeable Battery
Recycling Corporation (RBRC). At the end of your battery pack‘s useful life, return the battery pack
to a MILWAUKEE Branch Oce/Service Center or the participating retailer nearest you. For more
information, visit the RBRC web site at www.rbrc.org.

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TB-6W0500-I
OPERATING INSTRUCTIONS
Be sure to read instructions carefully, wear safety goggles, and keep ngers away from crimping
head.
ATTACH HEAD
1. Turn lever clockwise or counter clockwise so it sits at 12:00 position
2. Pull straight out
3. Slide crimping jaw into body
4. Slighty squeeze jaw together and push pin back in
5. Turn lever back to 6:00 position
1
1 2 3
54

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TB-6W0500-I
ATTACHING THE BATTERY TO THE TOOL
1. While pressing the two side buttons, pull out the battery cartridge. To replace the battery
cartridge, push the new cartridge rmly into place.
2. After inserting a battery cartridge, check that it is securely in place by pulling gently. Do not
press the side buttons when pulling the cartridge.
SHOULDER STRAP
Be sure to use the shoulder strap when using and/or transporting the tool.
ADVANCE TRIGGER AND RELEASE BUTTON
1. The crimp jaw closes when the trigger is pressed and stops closing when the trigger is
released.
2. To open crimp jaw, push the release button. The crimp jaw continues to retract as the release
button is held down. You may retract at any time even if there is no battery in the tool.
21

16
TB-6W0500-I
CRIMPING
1. Retract the ram fully by pressing the release button.
2. Insert dies by pushing die pin and slide ears of dies over the D3 nest die.
3. Place the connector between the dies.
4. Press the advance trigger and advance the ram so that the connector is held between the dies
and insert conductor into the terminal.
5. Press the advance trigger until the compression is completed. The jaw will automatically open
once crimp is complete.
6. Remove dies after crimp is complete by pressing die release buttons (see step two).

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TB-6W0500-I
TOOL MAINTENANCE
Daily maintenance:
• Use a soapy cloth to wipe away any oil that may be on the housing of the tool.
• After each crimping cycle wipe the crimping head jaws free of metal shavings.
• Wipe down all steel parts with WD-40.
• Store the tool in a non-humid environment.
The tool should provide many years of service when given the proper maintenance and
care. Should you experience any diculty with the operation and maintenance of this
tool, contact our customer service department (see back cover).

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TB-6W0500-I
BATTERY STATUS LIGHTS
Fault Cause / Solution
At the end of the cutting cycle
No light No malfunction
Red flashing light Charge / substitute the battery (about 10% of the capacity)
Red light Flat battery
After inserting the battery
Green light No malfunction
Red light Charge /replace the battery
MAINTENANCE REQUIREMENT LIGHTS
Fault Cause / solution
At the end of the cutting cycle
green light Operating value OK
green/red flashing Operating value OK and interval of maintenance passed/due
red flashing Operating value at limit / contact customer service
red light Operating value faulty or hardware malfunction / request
assistance
orange light Temperature error / warm or cool the tool
After inserting the battery
green light No malfunction
orange light Temperature error / warm or cool the tool
Tool Reset:
The cable cutter turns off and remains blocked. The service red or orange LED‘s light up.
Work can resume only after replacing the battery or after removing it for a moment and
then reinserting it. If, after you reset the tool, the issue persists contact the customer
service department (see back cover).

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TB-6W0500-I
SOFTWARE INSTALLATION
System requirements
Before proceeding with the installation of the software, assure that your PC satisfies the
following requirements:
Operating system: Windows 2000, Windows XP, Windows Vista,
Windows 7
CPU: Pentium 4, at least 1,7 GHz
Memory: 512MB or more (1 GB or more recommended)
Hard Drive: 200 MB (1 GB recommended)
Screen resolution: 1024 x 768 or higher, at least 65,535 colors
Other: CD-ROM, USB 2.0
How to Download Software
1. Go to www.Ilsco.com
2. Click the Technical Resources tab
3. Under the Technical Resources header, click on the Tool Software link
4. Locate your tool‘s software
Plug & Play
Once you have completed the installation of the software, the computer will
automatically recognize the battery operated tool, allowing you to update the
data and programs.

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TB-6W0500-I
TOOL PARTS BREAKDOWN
1
2
3 4 5 6 7
2 8 2 3
9
10 11
12 13 15 16 17 18 14