Thomas & Betts BAT22 6 Battery-Powered Crimping Tool User Manual

Tel: +44 (0)117 977 4647
Fax: +44 (0)117 977 5582
Email: [email protected]
Website: www.cablejoints.co.uk
www.thorneanderrick.co.uk
BAT22-6
Battery-Powered Crimping Tool
Read and understand all of the instructions
and safety information in this manual before
operating or servicing this tool.
Table of Contents
1.0 General Information . . . . . . . . . . . . . . . . . . . . . 2
1.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Purpose of this manual . . . . . . . . . . . . . . . . . . . . 2
1.4 Specification. . . . . . . . . . . . . . . . . . . . . . . . 2
2.0Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Charging the battery . . . . . . . . . . . . . . . . . . . . . 3
2.2 LED Display. . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Preparing cable . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Installing dies. . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Crimping cable . . . . . . . . . . . . . . . . . . . . . . . 4
3.0Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Each operating day. . . . . . . . . . . . . . . . . . . . . . 4
4.0Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Problems & Remedies. . . . . . . . . . . . . . . . . . . . . 4
5.0 Battery Maintenance. . . . . . . . . . . . . . . . . . . . . 5
5.1 Battery maintenance warning and cautions . . . . . . . . . . . . 5
6.0Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 5
6.1 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . 5
6.2 Pump housing unit, relief valve unit and piston pump assembly. . . . 6
6.3 Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . 6
7.0 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.0 Calibration Verification. . . . . . . . . . . . . . . . . . . 8
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1.0
1.1
GENERAL INFORMATION
1.2
DESCRIPTION
The BAT22-6 Battery-powered Crimping Tool is a
hand-held, self-contained crimping tool intended
to crimp terminals, splices, and disconnects on 22
AWG through 6 AWG wires using appropriate dies.
Crimping Head
Crimping Dies
(Not included.
Order separately,
See Table 1,
step 2.3)
18mm Die Pins
Ram
SAFETY
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.
1.3
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:
BAT22-6 Battery-powered Crimping Tool
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge.
1.4
13mm Die Pins
SPECIFICATION
Retract Button
Crimping Tool
Trigger
Length..................................................14” (356 mm)
Width................................................. 2-3/8” (60 mm)
Depth................................................ 3-1/8” (80 mm)
Mass/Weight (with battery)................2.8 lb. (1.3 kg)
Sound Level..............................75 dB (A) at 1 meter
Vibration.................................................... < 2.5 m/s2
Hydraulic Oil................................ Shell Tellus®* T 15
Crimping Capacities
Maximum Crimping Force...............1.5 tons (13 kN)
Average Crimping Time............................2 seconds
Average Crimps per Charge...... approximately 150
LED Display
Battery Lock
Battery Cartridge
Figure 1
Battery
Charging Voltage.............................................. 9.6 V
Charging Time........................................ 40 minutes
All specifications 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.
*Tellus is a registered trademark of Shell Oil Company
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2.0
OPERATION
WARNING
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.
Pinch points: Keep hands away from the crimping
head when crimping. Failure to observe this warning
could result in severe injury.
EYE PROTECTION: Wear eye protection when
operating or servicing this tool. Failure to wear eye
protection could result in serious eye injury from flying
debris or hydraulic oil.
2.1
CHARGING THE BATTERY
Read all instructions supplied with the battery charger.
2.3
An incomplete crimp can cause a fire.
•Use proper die, connector, and cable combinations.
Improper combinations can result in an incomplete
crimp.
•The relief valve will sound to indicate a completed crimp.
If you do not hear the sound of the relief valve, the crimp
is not complete.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
2.2
LED DISPLAY
This tool is equiped with a special circuit board incorporating
several important features to inform the user about the current
status of the unit. The LED signals in the following cases:
Signal
PREPARING CABLE
Follow the lug manufacturer’s instructions for
appropriate cable strip length.
Duration
When it occurs
What it means
a few seconds of
flashing
battery insertion
self check - O.K.
glowing for 20 seconds
after crimp
battery discharged
flashing for 20 seconds
(2 Hz)
after crimp
time for inspection and
preventive maintenance
20 sec. glowing and
flashing intermittently
after crimp
battery discharged - time for
inspection and preventive
maintenance
CAUTION
• Do not operate the tool without dies. Damage to the ram or crimping head can result.
• Do not operate with the crimping head open. Damage to the ram or seals can result.
• This tool is not designed for continuous use. After 100 crimping cycles, allow the crimping tool to cool for 15 minutes.
•Do not place the tool in a vise. The crimping tool is designed for hand-held operation.
• This tool may be used in damp or wet environments; however, we recommend air-drying the tool before use if it becomes soaked.
• Use this tool for manufacturer’s intended purpose only.
FAILURE TO OBSERVE THESE PRECAUTIONS MAY RESULT IN INJURY OR PROPERTY DAMAGE.
2.4
INSTALLING DIES
1. Select the proper die set for the intended crimping
operation, see Table 1.
2. Remove screw, washer, and die mounting pins from the
crimping head.
3. Extend the ram partially by momentarily pulling the
trigger to access the screw, washer, and pins in the ram,
and remove.
4. Insert one die half into the partially extended ram.
Install the 13 mm pins**, screw and washer through the
ram mounting holes and the die half. Tighten screw
snugly. Retract ram fully by depressing retract button.
5. Insert remaining die half into the crimping head, and
install with 18 mm pins**, screw and washer. Tighten
screw snugly.
** DIE2001, DIE2500 do not use die mounting pins.
When installing the dies, proceed as described above but
do not tighten screws fully. After die set is in place, ensure
dies are properly aligned and extend the ram until the dies
engage under some pressure.
Tighten screws snugly.
BAT22-6 Die Ordering Information
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
TABLE 1
CAUTION
It does not matter in which location the indentor or nest
half of the die set is installed, either crimping head or
ram. However, it is very important that the largest nest
be positioned away from the open side of the crimping
head, closest to the head itself. Failure to do so will
result in premature head failure.
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2.5
CRIMPING CABLE
1. Insert the properly assembled connector into the crimping
head.
2. Pull the trigger to make the crimp.
NOTE: If it is necessary to retract the ram before a crimping
cycle is complete, push the retract button which will result in
the complete retraction of the ram.
Sta-Kon® Terminals
WARNING
Keep hands away from the crimping
head when crimping. Failure to observe
this warning could result in severe injury.
3. Hold the trigger down until the crimping tool achieves
pressure relief, which is accompanied by an audible “pop”.
4. The crimping tool returns automatically.
5. Position the crimping tool for the next crimp. Repeat
Steps 2 and 3 for the next crimp (see Figure 1).
One crimp required.
Two crimps required, one
crimp on each side.
Non Insulated
Non Insulated
Crimp
Insulated
Insulated
Crimp
Figure 2
Maintenance
3.1
EACH Operating Day
Crimp
Crimp
AFTER USE:
1. Wipe all tool surfaces clean with a damp cloth
and mild detergent.
WARNING
Do not use solvents or flammable
cleaners to clean the crimping tool body.
Solvents could ignite, causing serious
injury or property damage.
WARNING
Skin injection hazard:
Do not use hands to check for oil leaks.
High pressure oil easily punctures skin
causing serious injury. If injured, seek
medical help immediately to remove oil.
Crimp
Crimp
3.0
BEFORE USE:
1. Inspect dies for wear or damage such as cracks,
gouges, or chips.
2. Inspect the tool for damage or leaks. If damage
is detected, return the tool to an authorized
Thomas & Betts service center for inspection.
Sta-Kon® Splice
2. Fully retract the ram. Place the tool in the
carrying case. Store in a cool, dry place.
3. Charge the battery.
MONTHLY:
Thoroughly clean all surfaces.
ANNUALLY OR AFTER 10,000 CRIMPS:
Return the tool to an authorized Thomas & Betts
service center for inspection.
4.0
TROUBLESHOOTING
4.1
PROBLEMS & REMEDIES
Problem
Probable Cause
Probable Remedy
Dirt, Contaminants, etc., in ram area of tool.
Clean tool.
Crimping tool battery contacts damaged.
Reform contacts.
Tool components worn or damaged.
Return tool to an authorized Thomas & Betts service center.
Battery contacts dirty
Clean contacts with nonflammable contact cleaner or pencil eraser
Battery discharged
Charge or replace battery
Oil level is low.
Return to an authorized T&B Tool Service Center.
Air in hydraulic system.
Pull trigger and hold retract button simultaneously. Hold for approximately 10
seconds.
LED glows for 20 seconds.
Battery charge low.
Charge or replace battery.
Tool loses oil.
Damaged internal seal.
Return tool to an authorized T&B Tool Service Center.
Tool is inoperative.
Dies stop during operation.
For parts and service, contact Thomas & Betts Tool Service center at 1-800-284-TOOL (8665).
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5.0
BATTERY MAINTENANCE
5.1
BATTERY MAINTENANCE WARNINGS AND CAUTIONS
WARNING
CAUTION
Do not allow conductive objects to contact the battery
terminals.
• Do not immerse the batteries in liquid. Liquid may
create a short circuit and damage the battery.
If batteries are immersed, contact your service
center for proper handling.
• Do not place the battery into a pocket, tool pouch,
or tool box with conductive objects. Conductive
objects may create a short circuit and damage the
battery.
• Do not place a battery on moist ground or grass.
Moisture may create a short circuit and damage
the battery.
Failure to observe these precautions may result in
injury or property damage.
Do not dispose of batteries in a fire. They will vent
fumes and may explode.
Failure to observe this warning could result in severe
injury from harmful fumes or burns from flying debris.
CAUTION
• Do not store the battery at more than 60ºC (140ºF).
Damage to the battery can result.
• Do not use another manufacturer’s charger. Other
Manufacturer’s chargers may overcharge and
damage the battery
• Do not attempt to open the battery. It contains no
user-serviceable parts.
Failure to observe these precautions may result in
injury or property damage.
6.0
ILLUSTRATIONS
6.1
MAIN ASSEMBLY
15
145
140
144
13
141
12
16
147
140
143
142
146
10
148
99
17
97
11
14
7
90
92
141
91
93
103
102
95
100
103 101
94
98
100
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6.2 PUMP HOUSING UNIT, RELIEF VALVE UNIT, AND PISTON PUMP ASSY.
39
38
36
34
37
35
33
32
30
31
50
55
52
120
121
122
53
123
54
56
51
50
6.3
MOTOR ASSEMBLY
79
78
76
74
73
72
71
70
75
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7.0
PARTS LIST
KEY
PART NO.
7*
501 2005.0
Bushing with seal
1
10
500 1928.7
Lever, relief valve
1
11
500 1929.5
Screw
1
12
520 2664.0
Switch
13
TA02638
Decal, identification
14
TA02637
15
16
TA02655
17
DESCRIPTION
QTY
KEY
PART NO.
DESCRIPTION
QTY
500 5111.3
Head unit (includes 90 – 30)
90
500 1922.8
Bolt, shoulder
1
91
500 1915.5
Cap
1
1
92
500 1916.3
Compression spring
1
1
93
500 1912.0
Compression spring
1
Decal, identification
1
94
500 1911.2
Washer
1
Decal, warning
1
95
500 5113.0
Crimping head
1
Decal, specification
1
97
500 5115.6
Die holder
1
Decal, pinch hazard
1
98
500 1929.5
Screw
1
99
Pin, 13 mm
2
5001892.2
Relief valve unit (includes 30 – 39)
100
Pin, 18 mm
2
30*
500 5862.2
Seal
1
101
Screw, M4 x 20
1
31
500 1955.4
Valve seat
1
102
Screw, M4 x 16
1
32
500 1946.5
Needle Valve
1
103
Washer
2
33
500 1954.6
Plunger
1
34
501 0377.6
Spring
1
500 1899.0
Piston pump assembly (includes 120 – 123)
35
500 7015.0
Lock washer
2
120
500 1931.7
Piston pump
1
36*
500 6370.7
O-ring
1
121
500 1901.5
Spring
1
37*
500 1906.6
O-ring
1
122
500 1930.9
Piston pump housing
1
38
500 1952.0
Pressure relief
1
123*
500 0369.5
Piston seal
1
39
501 0914.6
Screw
1
500 5116.4
Housing unit, blue (includes 140 – 148)
500 1894.9
Pump housing unit (includes 50 – 56)
140
500 4207.6
Screw
4
50*
500 1972.4
Clamp
2
141
500 1976.7
Screw
2
51
500 1902.3
Screw
1
142
500 4396.0
Compression spring, DA5.5 x L14.0
1
52
501 0916.2
Threaded bushing
1
143
500 1934.1
Link, trigger
1
53
500 1957.0
Pump block
1
144
Lever, battery release
1
54
501 0930.8
Threaded bushing
1
145
Housing half
1
55
501 0931.6
Screen
1
146
Housing half
1
56
500 1944.9
Reservoir
1
147
Button, relief valve
1
148
Cover, trigger
1
500 1895.7
Motor assembly (includes 70 – 79)
70
500 1965.1
Retaining ring
1
71
500 1958.9
Pin
1
72
500 1961.9
Motor cap
1
73
500 1953.8
Disc housing
1
74
500 1962.7
Disc
2
75
500 1979.1
Screw
2
76
500 1974.0
Gear lube, 1.5 g
1
78
501 0933.2
Motor adapter
1
79
500 1896.5
Motor, electric
1
*
500 2724.7
Seal kit (includes items marked with an
asterisk)
500 1965.1
Die pin kit (includes 99 – 103)
500 5126.1
Pin
501 1834.0
Decal kit (includes 13 – 17)
500 5117.2
Case with inserts
500 5121.0
Decal, case
520 2663.8
9.6 V battery
520 2770.0
12 V charger 120 VAC
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8.0
CALIBRATION VERIFICATION
NOTE: Calibration verification procedure should be performed whenever the tool is damaged or damage is suspected.
8.1
WARNING
This tool is equipped with the SHURE STAKE®
full stroke compelling mechanism.
Keep fingers clear of die nest during gaging
procedure.
8.2
VISUAL INSPECTION
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.
GAGING PROCEDURE
NOTICE: 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, modification or alteration of the
tool or use by the customer in a manner other than as
specified 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, modified or altered tool or improper usage
or such tool.
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 specified 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.
TABLE 2
TABLE 3
TABLE 4
DIE2001 Gaging Requirements
DIE2002 Gaging Requirements
DIE2007 Gaging Requirements
NEST
GAGING
MIN. – MAX.
WIRE SIZE
NEST
GAGING
MIN. – MAX.
WIRE SIZE
NEST
GAGING
MIN. – MAX.
WIRE SIZE
RED
.100 – .103
#22 – #18 AWG
A
.062 – .067
#22 – #18 AWG
RED
.190 – .196
#8 AWG
BLUE
.117 – .120
#16 – #14 AWG
B
.084 – .089
#16 – #14 AWG
BLUE
.212 – .218
#6 AWG
YELLOW
.149 – .152
#12 – #10 AWG
C
.110 – .115
#12 – #10 AWG
TABLE 5
TABLE 6
DIE2500 Gaging Requirements
DIE2005 Gaging Requirements
NEST
GAGING
MIN. – MAX.
WIRE SIZE
NEST
GAGING
MIN. – MAX.
WIRE SIZE
RED
.080 – .088
#22 – #16 AWG
B
.083 – .089
#16 – #14 AWG
BLUE
.091 – .099
#16 – #14 AWG
C
.118 – .124
#12 – #10 AWG
YELLOW
.119 – .127
#12 – #10 AWG
D-E
.176 – .181
#8 – #6 AWG
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 notification of any warranted defect, Thomas & Betts will, at its option, repair or replace the defective product. Misuse, misapplication or
modification 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.
FOR PARTS OR SERVICE,
Tel: +44 (0)117
977 4647
CONTACT TOOL SERVICE CENTER AT 1-800-284-TOOL
(8665)
Thomas & Betts Corporation
Memphis, Tennessee
www.tnb.com
© 2013 Thomas & Betts Corporation. All Rights Reserved.
Fax: +44 (0)117 977 5582
Email: [email protected]
Website: www.cablejoints.co.uk
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