Thomas&Betts Sta-Kon PAIR22-6 User manual

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Operating Instructions
for PAIR22-6
AIR-POWERED CRIMPING TOOL
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Page
1.0 GENERAL INFORMATION....................................... 2
1.1 Description
1.2 Safety
1.3 Purpose of this Manual
1.4 Specication
1.5 Tool Warranty
1.6 Identication
2.0 IMPORTANT SAFETY INFORMATION.........................3
2.1 Safety Alert Symbol
2.2 Warnings & Cautions
3.0 OPERATION ....................................................... 4 & 5
3.1 Set up Tool
3.2 Die Installation
3.3 Tool Operation
3.4 Preparing Cable
3.5 Sta-Kon®Ordering Information
3.6 Crimping Cable
Page
4.0 MAINTENANCE .................................................. 5 & 6
4.1 Each Operating Day
4.2 Monthly
4.3 Field Service
4.4 Fill Tool with Hydraulic Oil
5.0 TROUBLESHOOTING .............................................6
5.1 Table 1
6.0 CALIBRATION VERIFICATION ............................... 6 & 7
6.1 Safety
6.2 Visual Inspection
6.3 Gaging Procedure
6.4 Gaging Tables
Table of Contents

GENERAL INFORMATION1.0
The PAIR22-6 Air-powered Hydraulic Crimping Tool
is a portable, Sta-Kon®crimping tool intended to
crimp terminals on 22 AWG thru 6 AWG wire using
appropriate dies.
DESCRIPTION1.1
Safety is essential in use and maintenance of
Thomas & Betts tools and equipment. This manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
1.2 SAFETY
PURPOSE OF THIS MANUAL
This manual is intended to familiarize all personnel
with the safe operation and maintenance procedures
for the following Thomas & Betts tool:
PAIR22-6 Air-powered Crimping Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge.
1.3
WARNING
NEVER EXCEED 100 PSI
Crimping Tool
Length.................................................14" (356 mm)
Mass/Weight.....................................2.5 lb (1.13 kg)
Crimping Capacities
Maximum Crimping Force.... 1.25 tons@100 psi (16 kn)
Normal Operating Pressure.............................85-90 psi
SPECIFICATION1.4
TOOL WARRANTY1.5
WARRANTY: Thomas & Betts sells this product with the understanding that
the user will perform all necessary tests to determine the suitability of this
product for the user's intended application. Thomas & Betts warrants that this
product will be free from defects in materials and workmanship for the period
stated on the enclosed warranty card. Upon prompt notication of any
warranted defect, Thomas & Betts will, at its option, repair or replace the
defective product. Misuse, misapplication or modication of Thomas & Betts
products immediately voids all warranties.
Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE
WARRANTY CONCERNING THIS PRODUCT, AND IS IN LIEU OF ALL
OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE SPECIFICALLY
DISCLAIMED. LIABILITY FOR BREACH OF THE ABOVE WARRANTY IS
LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT,
AND UNDER NO CIRCUMSTANCES WILL THOMAS & BETTS BE LIABLE
FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
IDENTIFICATION
All specications are nominal and may change as
design improvements occur. Thomas & Betts shall
not be liable for damages resulting from
misapplication or misuse of its product..
1.6
Release
Knob
Yoke
Spring
Loaded
Die Support
Actuating
Handle
FIGURE 1
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IMPORTANT SAFETY INFORMATION2.0
This symbol is used to call your
attention to hazards or unsafe
practices which could result in an
injury or property damage. The
signal word, dened below,
indicates the severity of the
hazard. The message after the signal word provides
information for preventing or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result in
severe injury or death.
SAFETY ALERT SYMBOL2.1
Hazards which, if not avoided, COULD result in severe
injury or death.
Hazards or unsafe practices which, if not avoided, MAY
result in injury or property damage.
DANGER
WARNING
CAUTION
WARNINGS & CAUTIONS2.2
Read and understand all of the
instructions and safety information in
this manual before operating or
servicing this tool.
Failure to observe this warning could
result in severe injury or death.
WARNING
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use proper personal
protective equipment.
Failure to observe this warning could
result in severe injury or death.
WARNING
Do not use solvents or ammable
liquids to clean the crimping tool.
Solvents or ammable liquids could
ignite and cause serious injury or
property damage.
WARNING
An incomplete crimp can cause a re.
•Use proper die, connector, and cable
combinations. Improper combinations can
result in an incomplete crimp.
Failure to observe these warnings could result in
severe injury or death.
WARNING
Do not perform any service or maintenance other
than as described in this manual. Injury or damage to
the tool may result.
Failure to observe this precaution may result in injury
or property damage.
CAUTION
NOTE: Keep all decals clean and legible, and replace
when necessary.
Pinch points:
Keep hands away from the crimping
head when crimping.
Failure to observe this warning could
result in severe injury or death.
WARNING
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from ying
debris or hydraulic oil.
WARNING
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The tool is shipped fully assembled (less dies).
1. Remove tool assembly from shipping container.
2. Position the tool on a workbench or table.
3. Connect air supply line to the inlet at the rear of
the tool.
NOTE: Do not add airline extensions between
the foot pedal and lter/regulator/lubricator
assembly. This will prevent line pressure drops.
NOTE: Cylinder and pneumatic components are
designed to operate without lubrication.
If you choose to lubricate use a quality grade,
non-detergent, SAE #10 parafn base oil.
Rate of lubrication should not exceed one drop
per 100 crimping cycles.
SET UP TOOL3.1
1. Disconnect air supply
2. Install die nest into spring loaded support and die
indentor into yoke using screws provided. Screws
should be lightly hand tightened at this time.
3. Ensure that the die nest and indentor are engaged
and aligned. Securely tighten screws so that dies
will not move within support blocks.
NOTE: Some dies require use of special headed
pins combined with the screws (See Figure 2).
4. Connect air supply
.
DIE INSTALLATION3.2
Wear eye protection when
operating or servicing this tool.
Failure to wear eye protection
could result in serious eye injury
from ying debris or hydraulic oil.
WARNING
Headed Pins
FIGURE 2
1. To operate the tool properly, it is essential to
hold the actuating handle (see Figure 1) down
until the tool cycles completely. This assures a
sustained volume of air in the cylinder at full
pressure to complete the crimp.
2. The tool is equipped with a spring loaded lower
die support to hold the terminal.
TOOL OPERATION3.3
Follow the terminal manufacturer's instructions for
appropriate cable strip length.
PREPARING CABLE3.4
• Inspect tool and dies before use. Replace any
worn or damaged parts. A damaged or
improperly assembled tool can break and strike
nearby personnel.
• Failure to observe this warning could result in
severe injury or death.
•
Do not attempt to connect the tool to an
energized air line.
• Disconnect tool from air supply when servicing
or changing dies.
WARNING
• Do not operate the tool without dies. Damage
to the ram or crimping head can result.
• Never exceed 100 psi operating pressure.
• Use this tool for manufacturer's intended
purpose only
.
Failure to observe these precautions may result in
injury or property damage.
CAUTION
CAT. NO. DESCRIPTION
DIE2001 Insulated 22-10 AWG Sta-kon®Terminals
DIE2002 Non-insulated 22-10 AWG Sta-Kon®and
Spec-Kon Terminals
DIE2005 Non-insulated 16-6 AWG Sta-Kon®and
Spec-Kon Terminals
DIE2007 Insulated 8-6 AWG Sta-Kon®Terminals
DIE2500 Insulated 22-10 AWG Spec-Kon®Terminals
STA-KON®ORDERING INFORMATION3.5
OPERATION3.0

3.0 OPERATION.....Continued
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1. Using release knob (see Figure 1), open spring
loaded lower die.
2. Insert the terminal into the proper crimping head
die nest, and allow lower die to close.
3. Insert stripped cable into the terminal
4.
Depress and hold the actuating handle (see Figure 1)
until tool ram extends completely. Repeat Step 4 for
the next crimp (see Figure 3).
CRIMPING CABLE3.6
Sta-Kon®Terminals
One crimp required.
Crimp
Crimp
Non Insulated Insulated
Sta-Kon®Splices
Two crimps required, one crimp on each side.
Crimp
Crimp
Crimp
Crimp
Non Insulated
Insulated
FIGURE 3
An incomplete crimp can cause a re.
• Use proper die, connector, and cable
combinations. Improper combinations can
result in an incomplete crimp.
• The tool will cycle completely to indicate a
successful crimp. If tool does not cycle
completely, crimp is unsuccessful.
Failure to observe these warnings could result in
severe injury or death.
WARNING
4.0 MAINTENANCE
Before use:
1. Inspect dies for wear or damage such as cracks, gouges, or chips.
2. Inspect the tool for damage or air leaks. If damage is detected, return the tool to an authorized Thomas & Betts
service center for inspection, 1-800-284-TOOL (8665).
3. Ensure all fasteners are properly tightened.
4. Make sure spring loaded die holder is free to travel without binding. Lubricate ram if needed.
After use:
1. Wipe all tool surfaces clean with a damp cloth and mild detergent.
IMPORTANT: See warning located in Step 4.2.
EACH OPERATING DAY4.1
Before use:
Thoroughly clean all surfaces.
MONTHLY4.2
Do not use solvents or ammable
cleaners to clean the crimping tool
body. Solvents could ignite, causing
serious injury or property damage.
WARNING
FIELD SERVICE4.3
Before use:
1. These are precision tools and must be handled
acordingly. Therefore, all maintenance must be
performed by qualied personnel only.
NOTE: To assure proper compression, all tools
have a low oil warning device mounted on the
side of the air cylinder (see Figure 4). This device
contains a red rod which extends when the
hydraulic oil needs replenishment.

4.0 MAINTENANCE.....Continued
FILL TOOL WITH HYDRAULIC OIL4.4
1. Unscrew hydraulic cylinder from air cylinder
(see Figure 4).
2. Hold tool upright with air cylinder ar top; pull the
two cylinders completely apart.
3. Pour hydraulic oil (T&B Cat. No. 21061) through
opening in packing gland until oil level reaches
top of gland.
4. Insert piston rod into gland opening and screw
air cylinder onto hydraulic cylinder.
Hand tighten only.
It is essential that the piston rod be inserted into
hydraulic cylinder opening before reassembling tool.
CAUTION
Low Oil
Warning
Device
Gland
OIpening
Hydraulic
Cylinder
Air
Cylinder
Piston Rod
FIGURE 4
5.0 TROUBLESHOOTING
TABLE 15.1
Problem Probable cause Probable Remedy
Tool is inoperative.
Insufcient air pressure Ensure air supply of 85-90 psi to tool.
Tool components worn or damaged. Return tool to an authorized Thomas & Betts service center.
Oil level low. Add oil.
For parts or service, contact Thomas & Betts tool service center at 1-800-284-TOOL (8665).
SAFETY6.1
NOTE: Calibration verication procedure should be
performed whenever the tool is damaged or damage
is suspected.
This tool is equipped with the SHURE
STAKE®full stroke compelling
mechanism.
Keep ngers clear of die nest during
gaging procedure.
WARNING
VISUAL INSPECTION6.2
Tool must be free of cracks, sharp edges and other
obvious imperfections that may affect performance
of the tool. Nest area must be free of burrs, dents or
scratches.
6.0 CALIBRATION VERIFICATION
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© 2014 Thomas & Betts. All Rights Reserved.
GAGING PROCEDURE6.3
NOTE: Wipe die nest before gaging.
1. Cycle tool until dies bottom.
2. Using gage pins, insure that each nest meets the
gaging requirements as specied in TABLE 2, 3,
4, 5, or 6 per the corresponding die.
UPON SUCCESSFUL COMPLETION OF THE
ABOVE PROCEDURE, THE PREVIOUS
CALIBRATION OF THE TOOL IS VERIFIED
NOTE: If tool fails any of the above tests, do not
attempt repair or adjustment. Call the nearest
Thomas & Betts Tool Service Center to arrange for
repair service. Any change, modication or alteration
of the tool or use by the customer in a manner other
than as specied by Thomas & Betts shall void all
warranties express or implied and the customer shall,
therefore, assume all liability for any damage or injury
caused by said change, modied or altered tool or
improper usage or such tool.
TABLE 2
DIE2001 GAGING REQUIREMENTS
NEST GAGING
MIN. – MAX. WIRE SIZE
RED .100 – .103 #22 – #18 AWG
BLUE .117 – .120 #16 – #14 AWG
YELLOW .149 – .152 #12 – #10 AWG
TABLE 4
DIE2007 GAGING REQUIREMENTS
NEST GAGING
MIN. – MAX. WIRE SIZE
RED .190 – .196 8 AWG
BLUE .212 – .218 6 AWG
TABLE 3
DIE2002 GAGING REQUIREMENTS
NEST GAGING
MIN. – MAX. WIRE SIZE
A .062 – .067 #22 – #18 AWG
B .084 – .089 #16 – #14 AWG
C .110 – .115 #12 – #10 AWG
TABLE 5
DIE2500 GAGING REQUIREMENTS
NEST GAGING
MIN. – MAX. WIRE SIZE
RED .080 – .088 #22 – #18 AWG
BLUE .091 – .099 #16 – #14 AWG
YELLOW .119 – .127 #12 – #10 AWG
TABLE 6
DIE2005 GAGING REQUIREMENTS
NEST GAGING
MIN. – MAX. WIRE SIZE
B .083 – .089 #16 – #14 AWG
C .118 – .124 #12 – #10 AWG
D-E .176 – .181 #8 – #6 AWG
GAGING TABLES6.4
6.0 CALIBRATION VERIFICATION.....Continued
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NOTES:
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com