Wesco Nicopress 5606 User manual

NICOPRESS®
MODEL 5606
BATTERY POWERED COMPRESSION TOOL
INSTRUCTION No. 5606
www.nicopress.com
THE NATIONAL TELEPHONE SUPPLY COMPANY

Instruction No. 5606 5606 BATTERY COMPRESSION TOOL 2 of 10
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TABLE OF CONTENTS
I. SAFETY AND WARNING REMINDERS........................................................................................................... 2
II. SPECIFICATIONS AND FEATURES............................................................................................................... 3
III. OPTIONAL ACCESSORIES............................................................................................................................. 3
IV. OPERATING INSTRUCTIONS ........................................................................................................................ 4
V. PROPER CRIMPING........................................................................................................................................... 5
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. Always wear safety eye protection at all times.
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 25º F (-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 THE NBP-1 BATTERY CARTRIDGE:
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 NCH-1 CHARGER:
1. This charger is for charging battery cartridge NBP-1 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-95ºF (10º-35º C). Charging time is
approximately 50 to 60 minutes for the NBP-1.
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. 5606 5606 BATTERY COMPRESSION TOOL 3 of 10
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II. SPECIFICATIONS AND FEATURES
1.Output Force — 6 ton
2.Weight — 8.2 lbs. with Battery
3. Size — 22”L x 4”H x 2.5”W
FEATURES
1. One Hand Operation.
2. Operates in confined space
3. Fully Enclosed Weather Resistant Housing.
4. Accepts Nicopress 6 ton compression dies.
5. Molded Plastic Case with Die Compartment.
6. LED Work Lights
III. OPTIONAL ACCESSORIES
BATTERY CARTRIDGE
NBP-1 BATTERY CHARGER NCH-1
Battery Cartridge (NBP-1), two included with tool.
Battery type: Lithium Ion
Voltage: 15.2V DC
Rated current: 3.0 Ah
Charge time: 50 to 60 min.
Battery Charger (NCH-1), one included with tool
Input voltage: 120 or 240 VAC single phase

Instruction No. 5606 5606 BATTERY COMPRESSION TOOL 4 of 10
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IV. OPERATING INSTRUCTIONS
CHARGING THE BATTERY
1. Insert the plug end into a 120V power source. The POWER indicator lights up green with
power.
2. To charge a drained battery, insert the battery into the charger. The READY indicator flashes
green with 90% charge and solid green when fully charged. The charging will be completed
in approximately 50 to 60 minutes.
3. The CHARGE/FAULT indicator shows amber when the battery is charging, or flashing
amber if the battery is too hot to be charged and must cool to room temperature before
charging.
4. The CHARGE/FAULT indicator shows a battery fault with a quick flashing amber.
ATTACHING THE BATTERY CARTRIDGE
1. While pressing the latch, pull out the battery cartridge. To replace the battery cartridge, push
the new cartridge firmly into place.
2. After inserting a battery cartridge, check that it is securely in place by pulling gently. Do not
press the latch when pulling the cartridge.
TRIGGER AND RELEASE BUTTON
1The ram advances when the trigger is pressed and stops when the trigger is released.
2To retract the ram, push the release button. The ram continues to retract while the release
button is pressed.

Instruction No. 5606 5606 BATTERY COMPRESSION TOOL 5 of 10
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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 dies press the trigger and advance the ram so that the
connector is held between the dies and insert cable into the sleeve.
4. Press the trigger until the compression is completed. A clicking sound will be heard while
operating and will stop once the crimp is 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.
WIRE ROPE SPLICING
Because of the 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
02/17/2009 for cable constructions 3x7, 7x7, 7x19 and Federal Specification RR-W-410F dated
12-06-2007 for cable construction 6x19 IWRC. These test results were achieved using
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.

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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 of the wire.
To make a proper lap splice, pull the ends of the rope through 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
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 assure proper tensile strength.

Instruction No. 5606 5606 BATTERY COMPRESSION TOOL 7 of 10
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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
188-1.5-VB4
6-OVAL-B4 (1)
6-OVAL-B4 (1)
6-OVAL-B4 (1)
6-188-VB4 (1)
3/16
18-6-X
28-6-X
428-6-VX
188-6-VX
6-OVAL-X (2)
6-OVAL-X (2)
6-OVAL-X (2)
6-188-VX (2)
1/16
18-1-C
28-1-C
428-2-VC
188-2-VC
6-OVAL-C (1)
6-OVAL-C (1)
6-OVAL-C (1)
6-188-VC (1)
7/32 18-8-F2
28-8-F2
428-7-VF2
6-OVAL-F2 (2)
6-OVAL-F2 (2)
6-OVAL-VF2 (2)
3/32
18-2-G
28-2-G
428-3-VG
188-3-VG
6-OVAL-G (1)
6-OVAL-G (1)
6-OVAL-G (1)
6-188-VG (2 ov)
1/ 4
18-10-F6
28-10-F6
428-8-VF6
188-8-VF6
6-OVAL-F6 (3)
6-OVAL-F6 (3)
6-OVAL-F6 (4)
6-188-VF6 (4)
1/ 8
18-3-M
28-3-M
428-4-VM
188-4-VM
6-OVAL-M (2)
6-OVAL-M (2)
6-OVAL-M (2)
6-188-VM (2)
5/16
18-13-G9
28-13-G9
428-10-VG9
188-10-VG92
6-OVAL-G9 (4)
6-OVAL-G9 (4)
6-OVAL-G9 (4)
6-188-VG9 (4)
5/32
18-4-P
28-4-P
428-5-VP
188-5-VP
6-OVAL-P (2)
6-OVAL-P (2)
6-OVAL-P (2)
6-188-VP (2)
3/8
18-23-H5
28-23-H5
428-12-VH5
188-12-VH5
6-OVAL-H5 (5)
6-OVAL-H5 (5)
6-OVAL-H5 (5)
6-188-VH5 (5)
Stop Sleeves
Cable Size Stop Sleeve Stock # Compression Die/# of Presses Required
3/64 871-12-B4 6-OVAL-B4 (1)
1/16 871-1-C
878-2-VC 6-OVAL-C (1) 6-OVAL-C (1)
3/32 871-17-J
878-3-J 6-J (1) 6-J (1)
1/ 8 871-18-J
878-4-J 6-J (1) 6-J (1)
5/32 871-19-M
878-5-M 6-OVAL-M (1)
6- OVAL-M (1)
3/16 871-20-M
878-6-M 6- OVAL-M (1)
6- OVAL-M (1)
7/32 871-22-M 6- OVAL-M (2)
1/ 4 871-23-F6
878-8-VF6 6-STOP-F6 (2) 6- STOP -F6 (2)
5/16 871-26-F6
878-10-VF6 6- STOP -F6 (2) 6- STOP -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 6-1700-C (1) 1/ 4 1700-X 6-1700-X (2)
1/ 8 1700-M 6-1700-M (2) 5/16 1700-G3 6-1700-G3 (4)
3/16 1582-P 6-1582-P (2)

Instruction No. 5606 5606 BATTERY COMPRESSION TOOL 8 of 10
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TROUBLESHOOTING GUIDE
PROBLEM CAUSE SOLUTION
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
MOTOR RUNS, BUT
THE TOOL JAWS WILL
NOT ADVANCE
Defective Hydraulic
Circuit Consult Factory for Repair Service
Insufficient Hydraulic Oil Consult Factory for
Repair Service
MOTOR RUNS, TOOL
JAWS ADVANCE BUT
WILL NOT BUILD
PRESSURE Defective Suction Valve
or Bypass Cartridge Consult Factory for Repair Service
Defective Battery Charge or Replace
Battery
Bad Contact or Loose
Battery Connections Check all Connections and Wires
Check to Make Sure that
Switch is Properly
Aligned with Trigger
MOTOR WILL NOT
RUN AT ALL
Misaligned Switch
Consult Factory for
Repair Service
Tool Did Not Complete a
Full Cycle and Bypass
Press Trigger and allow
Tool to Bypass. Then
Release Tool Jaws.
Connector is Jammed in
Tool Jaws
Press and Hold Release
Trigger While Prying
Tool Jaws Apart.
TOOL JAWS WILL NOT
RELEASE
Release Trigger is Bent
or Misaligned Consult Factory for Repair Service

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MODEL 5606 WARRANTY
The 5606 Battery Tool has a 1 year warranty and the NBP-1 battery has a 5 year warranty.
NICOPRESS reserves the right to determine all warranty claims. Failure due to misuse, abuse or
repairs attempted by anyone other than NICOPRESS, render this warranty null and void. A
repaired or reconditioned battery operated hydraulic tool carries a one year warranty.
REPAIR AND WARRANTY CLAIMS
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 properly handled 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.
PLEASE RETAIN FOR YOUR RECORDS
Purchaser’s Name ________________________________________________
Address ________________________________________________
City, State, Zip ________________________________________________
Tool Model Number ________________________________________________
Serial Number ________________________________________________
Date Purchased From ________________________________________________
FACTORY MAINTENANCE SERVICE
A factory maintenance reconditioning service is available beyond the warranty period to
accommodate normal tool wear. Contact your authorized distributor for additional information
and details.
THE NATIONAL TELEPHONE SUPPLY COMPANY
5100 Superior Avenue, Cleveland, Ohio 44103
Phone: [phone] Fax: [phone]

Instruction No. 5606 5606 BATTERY COMPRESSION TOOL 10 of 10
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MODEL 5606 WARRANTY
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. You
will be given a Return Goods Authorization Number to assure that your merchandise will be
properly handled upon its receipt.
CAUTION: Make sure the product is packaged adequately so as to prevent damage or loss
during transit. The shipment must be prepaid and we recommend that it be insured. A cover letter
indicating the reason for the return should be included in order to facilitate repairs.
SEND THIS PORTION WITH ANY TOOL WHEN REQUESTING REPAIRS,
WARRANTY OR RECONDITIONING WORK.
PLEASE CALL OR FAX A NICOPRESS 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 _____