IBC600 6-TON IN-LINE CRIMPING TOOL

IBC600
6-TON IN-LINE
CRIMPING TOOL
USER MANUAL
Safety, Operation and Maintenance
© 2017 STANLEY Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
81140 1/2018 Ver. 2
TABLE OF CONTENTS
SAFETY SYMBOLS................................................................................................................................................4
SAFETY PRECAUTIONS........................................................................................................................................5
TOOL ANATOMY.....................................................................................................................................................6
SPECIFICATIONS & ACCESSORIES.....................................................................................................................7
OPERATION............................................................................................................................................................8
STANLEY CRIMP SOFTWARE...............................................................................................................................11
TROUBLESHOOTING............................................................................................................................................16
IBC600 PARTS ILLUSTRATION.............................................................................................................................17
IBC600 PARTS LIST...............................................................................................................................................18
IBC600 HYDRAULIC BODY ILLUSTRATION.........................................................................................................19
IBC600 HEAD UNIT ILLUSTRATION......................................................................................................................20
92821 CRIMPING JAW ILLUSTRATION................................................................................................................21
92822 CRIMPING JAW ILLUSTRATION................................................................................................................22
92823 CRIMPING JAW ILLUSTRATION................................................................................................................23
To fill out a product warranty validation form and for information on your warranty,
visit www.stanleyinfrastructure.com and select the Company tab > Warranty.
Note: The warranty validation record must be submitted to validate the warranty.
SERVICING: This manual contains safety, operation and routine maintenance instructions. STANLEY Infrastructure
recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized
and certified dealer. Please read the following warning.
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR
SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN
AUTHORIZED AND CERTIFIED DEALER.
For the nearest certified dealer, call STANLEY Infrastructure at (503) 659-5660 and ask for a Customer Service Representative.
IBC600 User Manual ◄ 3
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
This safety alert and signal word indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided,
may result in property damage.
This signal word indicates a situation which, if not avoided, will result in damage
to the equipment.
This signal word indicates a situation which, if not avoided, may result in damage
to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here.
maintenance personnel.
4 ► IBC600 User Manual
Keep these instructions in an area accessible to the operator and
SAFETY PRECAUTIONS
Tool operators must comply with precautions given in this
manual and on the stickers attached to the tool.
•
Do not use the tool, battery or battery charger for
purposes other than what is described in this manual.
These precautions are given for your safety. Review them
carefully before operating the tool.
•
Always keep critical tool markings, such as labels
and warning stickers, legible. Contact STANLEY for
replacement labels.
Do not use the tool while under the influence of drugs
or alcohol.
Supervising personnel should develop additional precautions
relating to the specific work area and local safety regulations.
Place the added precautions in the space provided on page
4.
The IBC600 6-Ton In-line Crimping Tool will provide safe
and dependable service if operated in accordance with
the instructions in this manual. Read and understand this
manual and stickers attached to the tool before operation.
Failure could result in injury or tool damage.
•
Use the tool in a work area without bystanders.
•
Do not operate the tool unless thoroughly trained or
under the supervision of an instructor. Establish a training
program for all operators to ensure safe operation.
•
Always wear safety equipment such as eye protection,
ear protection, head protection and safety shoes at all
times when operating the tool. Use gloves if necessary.
•
The operator must be familiar with all prohibited work
areas such as excessive slopes and dangerous terrain
conditions. Ensure that your footing is firm and you are
in balance at all times.
•
•
Do not use accessories or attachments other than those
recommended by STANLEY.
BATTERIES
•
Only charge batteries using a STANLEY recommended
battery charger.
•
Do not store batteries with metal objects, such as coins,
nails or keys. Fire can result if battery terminals are
shorted.
•
Do not charge a damaged battery. Recycle and replace
damaged batteries with batteries recommended by
STANLEY.
•
Do not incinerate or dispose of batteries in the garbage.
Recycle the batteries.
•
Do not expose the battery to temperatures over 265°F.
Batteries may explode at high temperatures.
•
Leakage of liquid from the battery may occur under
extreme use or high temperatures. If battery liquid gets
on your skin:
1. Wash quickly with soap and water.
2. If the liquid gets in your eyes, flush your eyes
with clean water for 10 minutes. Seek medical
attention immediately.
•
Do not inspect, clean or replace tool jaws while the
battery is connected. Accidental engagement of the tool
can cause serious injury.
•
•
Do not operate a damaged, improperly adjusted or
incompletely assembled tool.
•
Do not use the battery charger if the cord is damaged.
•
Never wear loose clothing that can become entangled in
the working parts of the tool.
•
Do not place the charger, or set items on or near the
charger, in such a way as to block airflow to the charger.
•
Keep all parts of your body away from pinch points. Long
hair or loose clothing can become drawn into the tool.
•
•
To avoid personal injury or equipment damage, all tool
repair, maintenance and service must be performed by
an authorized service center.
Do not use the charger with an extension cord unless
absolutely necessary. Use a cord with the proper wire
size for its length, as described in Table 1.
•
Never use the tool in the vicinity of flammable materials
or gases.
•
Do not use the tool or charge the tool battery in an
explosive atmosphere.
•
Cutting or severing of body parts is possible if proper
procedures are not followed.
Never open the battery.
BATTERY CHARGER
Length of Cord (Feet)
25
50
100
150
Wire Size (AWG)
18
18
18
16
Table 1: Extension Cord Wire Size
•
Do not open the charger or attempt to modify it in any
way.
•
Disconnect the charger from power before attempting
to clean it.
•
Do not connect the charger to a transformer or engine
generator.
IBC600 User Manual ◄ 5
TOOL ANATOMY
WHAT IS THE IBC600?
The IBC600 is a battery powered 6-Ton in-line crimping tool with interchangeable crimping jaws. IBC600 is capable of
crimping copper and aluminum connectors to 500 MCM and HTAPS to 4/0-4/0. The InteLED gives real time feedback
to the operator and alerts them to a possible bad crimp.
Crimping Jaws
Crushing Risk
Decal
DO NOT put fingers, hands or other body parts between
the jaws. Serious injury will result!
InteLED
Pin Lock
Trigger Lock
Trigger
Pressure Release
Tool Identification &
Warning Decal
USB Port
Battery
6 ► IBC600 User Manual
SPECIFICATIONS & ACCESSORIES
SPECIFICATIONS
Crimping Force......................................................................................................................................6 Tons (53 kN)
Tool Cycle Time.........................................................................................................................................4.5 seconds
Crimping Capacity....................................................................................Copper/Aluminum connectors to 500 MCM
HTAPS to 4/0-4/0
Battery Type.........................................................................................DeWalt 20V Max (2 Amp/hour or 5 Amp/hour)
Estimated Crimps per Charge............................................................................ 200 (2 Amp/hour), 450 (5 Amp/hour)
Tool Weight
with 2 Amp/hour battery............................................................................................................................. 7.15 Lbs.
with 5 Amp/hour battery............................................................................................................................. 7.70 Lbs.
Tool Length...................................................................................................................18.8 Inches (2 Amp/hour batt.)
19.6 Inches (5 Amp/hour batt.)
Maintenance Interval...................................................................................................................Every 30,000 Cycles
ACCESSORIES
D3/O Jaw............................................................................................................................................................92821
(Accepts standard “W” dies)
D3/BG Jaw.........................................................................................................................................................92822
(Accepts standard “W” dies)
Kearney/BG Jaw................................................................................................................................................92823
(Accepts Kearney and “W” dies)
2 Amp/hour DeWalt 20V Max Battery............................................................................................................. DCB203
5 Amp/hour DeWalt 20V Max Battery............................................................................................................. DCB205
5 Amp/hour DeWalt 20V Max Battery 2-pack.............................................................................................. DCB205-2
120V AC Charger............................................................................................................................................DCB115
12V DC Charger..............................................................................................................................................DCB119
Note: Only use battery chargers recommended by STANLEY.
Bucket Bag.......................................................................................................................................................... BB01
IBC600 User Manual ◄ 7
OPERATION
CHARGE BATTERY
Battery Charging
Battery Charged
Hot/Cold Delay
INSTALL CRIMPING JAW AND BATTERY
DO NOT install or change crimping jaws while the battery
is connected to the tool. Disconnect the battery BEFORE
installing or changing crimping jaws.
3
2
1. Pull back the pin lock to eject the jaw pin.
1
2. Insert the crimping jaw and lock the jaw pin.
3. Insert the battery pack.
8 ► IBC600 User Manual
OPERATION
2
CRIMPING
1
4
5
1. Set the Trigger Lock
Set the trigger lock BEFORE attaching
dies to the jaw!
2. Clip the die onto the Crimping Jaw.
Figure 1: Lock the Trigger
5. Press and hold the pressure release.
Note: Release the trigger to immediately stop the
tool. Press the pressure release at any time to open
the jaws.
DO NOT crimp live cables! IBC600 is
NOT a live-line tool!
3. Release the Trigger Lock.
4. Press and hold the trigger until the tool has finished.
InteLED System
The InteLED system shows the status of the crimp. The light ring will shine different colors depending on the status
of the crimp.
InteLED Light Ring
InteLED
Meaning
White
Crimping. InteLED will stay
lit for 30 seconds after a
crimp is complete.
Green
The crimp is good.
Red
IBC600 did not reach full
pressure. Crimp again.
IBC600 User Manual ◄ 9
OPERATION
CHECKING BATTERY CHARGE
Battery Check Button
75 - 100% Charged
51 - 74% Charged
Less than 50% Charged
Charge Battery
SECURE THE JAWS INTO PLACE (OPTIONAL)
3
Jaw Coupling
1
IBC600 jaws can be secured into place by inserting a
pin and set screw (supplied) into the jaw coupling. This
will prevent the user from unlocking the jaw pin and
removing the jaws.
1. Set the trigger lock and insert the jaws.
2. Lock the jaw pin into place.
3. Insert the pin and set screw to lock the jaw pin.
10 ► IBC600 User Manual
2
OPERATION
STANLEY CRIMP SOFTWARE
STANLEY Crimp software provides valuable data about
each crimp. It is also required to update the tool firmware.
INSTALLATION
1. Download the STANLEY Crimp software from the
STANLEY Infrastructure website.
www.stanleyinfrastructure.com/products/cordless-td
Note: STANLEY Crimp software requires a minimum
of Windows XP SP3 running with administrator
rights.
2. Follow the prompts to complete installation.
3. Connect IBC600 to a PC using a micro USB cable.
Note: InteLED will shine blue when connected.
IBC600 USB Connection
FIRST RUN
1. Run the software using the STANLEY Crimp
software icon on your Windows desktop.
2. You will be prompted to register your software. Left
click the “User Registration” button.
3. Fill out the registration form and click the “Register”
button.
USER SELECTION
1. Click the “New User” button.
2. Enter the required user information and click “Create”.
3. Select a user and click “OK”.
IBC600 User Manual ◄ 11
OPERATION
TOOL INFORMATION
1
2
The Tool Information tab displays important data about the IBC600.
1. Displays the product type, serial number and firmware version of the tool.
2. Basic data relating to the life and service interval of the tool.
TOOL USAGE DATA
1
3
2
12 ► IBC600 User Manual
OPERATION
The Tool Usage Data tab displays information about individual tool cycles.
1. Displays the total number of tool cycles, as well as completed and non-complete cycles.
2. The data log shows each cycle, up to 250,000 cycles. Each entry into the log includes;
•
Date and time of each crimp
•
If the cycle completed successfully
•
Amperage and Voltage of the tool during each crimp
•
Tool temperature at the end of each crimp
3. Data log sorting filters. Allows you to sort the crimp data in the data log.
WORKSITE REPORTS
1
IBC600 User Manual ◄ 13
OPERATION
The Worksite Reports tab allows you to group data log entries into a complete tool cycle report.
2
4
3
5
1. Click “Create Report”.
2. Select the date range of the job you are reporting.
3. Select the crimp cycles you want to include in the report.
4. Select a user and a worksite.
Note: If this is the first time using the software, press the “Worksites” button to create a worksite.
5. Enter notes about the job in the Remarks field.
6. Click “OK” when finished.
7
7. Select a report from the reports list.
8. Click “Print Report to PDF” to export the Worksite Report.
14 ► IBC600 User Manual
OPERATION
AVAILABLE UPDATES
1
2
The Available Updates tab will allow you to update the tool firmware and update STANLEY Crimp software.
1. Tool Firmware Update button. When clicked, this will begin to tool firmware update process. Do not unplug the
tool during this process.
2. Software Update button. When clicked, this will update the STANLEY Crimp software, if an update is available.
IBC600 User Manual ◄ 15
TROUBLESHOOTING
Problem
Solution
I can’t install the crimping jaw / The crimping jaw
doesn’t fit into the tool body.
Press and hold the pressure release to fully retract the
piston. Insert the jaw into the tool body.
The jaw pin won’t fit through the hole in the crimping
jaw.
Remove the crimping jaw. Ensure the two halves of the
crimping jaw are aligned.
The jaw pin wont spring back, even though I am pulling Ensure that the jaw locking hardware is removed (see
back on the pin lock.
page 10). Press and hold the pressure release to
fully retract the piston. Pull back on the pin lock to eject
the jaw pin.
The tool won’t crimp when I press the trigger.
Ensure the battery is charged. Disengage the trigger
lock.
The InteLED flashes yellow when I activate the tool.
The maintenance interval is about to elapse. Have the
tool serviced as soon as possible.
The tool repeatedly gives me bad crimps / The InteLED Ensure the battery is fully charged. Ensure the
flashes red after every crimp.
crimping jaw is properly installed and the die is
properly attached. If problem persists, have the tool
serviced as soon as possible.
The tool will not release pressure when the pressure
release is held.
Have the tool serviced immediately.
The tool is leaking hydraulic oil.
Have the tool serviced immediately.
The tool cannot connect to STANLEY Crimp software.
Ensure the tool is connected to the computer via the
USB port and that InteLED is blue. Your computer
may be downloading USB drivers. Check the Windows
system tray for download progress.
The tool is not saving crimp data.
Have the tool serviced as soon as possible.
16 ► IBC600 User Manual
97
166
4
100
10
110
165
44
99
164
50
72
71
75
63
156
34
52
42
40
41
63
111
157
105
108
153
86
47
78
24
50
67
110
76
69
68
81
78
75
86
152
106
136
23
44
107
IBC600 PARTS ILLUSTRATION
IBC600 User Manual ◄ 17
IBC600 PARTS LIST
ITEM
P/N
QTY
DESCRIPTION
ITEM
P/N
QTY
DESCRIPTION
4
62412DUB
1
Compression Spring
153
See page 19
1
23
77058
1
Shackle (Torque to 2
Nm)
Hydraulic Body
Assembly
156
See page 20
1
Head Unit
24
91410
1
USB Cover
157
92877
1
Outer Trigger Assembly
34
91585
1
Oil Tank
164
70884DUB
1
Roller Assembly
40
91586
1
Oil Tank Plug
165
75147
1
Piston
41
ZBINA405
1
Magnet Pin
166
91603
1
42
91616
1
Metal Clamp
Guiding Ring
(Torque to 25 Nm)
44
91611
1
Housing Set
47
J4450300X70
1
O-Ring 44.5 x 3
50
92878
1
Electronic Device
52
AIG1.5x7.8BR
1
Calibrated Pin
63
91617
2
Metal Clamp
67
AAIN20
1
Circlip
68
JSR122004
2
Lip Seal
69
JBS04.5
2
Sealing Washer
75
VAV03HC006
2
Screw
76
VAV04CB006
4
Screw (Torque to 2 Nm)
78
VAV04FH006
6
Screw (Torque to 2 Nm)
81
VAV3.5TC014ZN
7
Screw
86
91623
2
Membrane Support
100
62411DUB
1
Compression Spring
103
77070
1
Cam Holder
105
91647
1
STANLEY Logo Decal
106
91648
1
IBC600 Decal
107
91634
1
“Powered by DeWalt”
Right Decal
108
91635
1
“Powered by DeWalt”
Left Decal
109
91637
1
INTELED Left Decal
110
91636
1
INTELED Right Decal
111
77067
1
Cam
113
RBAM12262
1
Pin Stop
136
91465
1
Strap Ring
152
92833
1
Motor and Gearbox
Assembly
18 ► IBC600 User Manual
IBC600 HYDRAULIC BODY ILLUSTRATION
65
25
18
56
27
161
35
162
16
254
48
52
40
55
52
162
160
163
ITEM
P/N
QTY
DESCRIPTION
16
31318DUB
1
Spring
18
77286
2
Cam Roller
25
77065
1
Cam Box
27
91606
1
Release Lever
35
77086
2
Spring
40
91584
1
Hydraulic Body
48
77504
1
Spring
52
AIG2.5X13.8BR
2
Pin
55
AIG4X13.8BP
1
Calibrated Pin
56
AIG4X29.8BP
1
Calibrated Pin
65
J3100200
1
O-Ring 31 x 2
160
77805-01
1
Delivery Valve Unit
161
77076
1
Cross Head
162
77837
1
Pressure release valve
(Torque to 6 Nm)
163
77806-01
1
Succion Valve Unit
(Torque to 12 Nm)
254
92875-11
1
Valve Unit
(Torque to 12 Nm)
IBC600 User Manual ◄ 19
IBC600 HEAD UNIT ILLUSTRATION
15
9
12
10
8
11
7
15
5
3
14
8
6
2
1
13
4
20 ► IBC600 User Manual
ITEM
P/N
QTY
DESCRIPTION
1
77035-02
1
Toothed Wheel
2
77394
1
Axis for jaws set
3
78476-01
1
Pull Tab
4
78586
1
Spring
5
84015DUB
1
Spring
6
91437
1
Plug
7
91440
1
Spacer Tube
8
91591
2
Half Flange
9
AIG1.5X7.8BR
2
Calibrated pin
10
AIG3x12.8BP
1
Calibrated Pin
11
AIG3.5x23.8BR
2
Calibrated Pin
12
VAV04BT006FF
1
Screw
13
VAV04EB010
1
Screw
14
VAV04CB015
1
Screw
15
VAV04HC010
4
Screw
92821 CRIMPING JAW ILLUSTRATION
1
1
2
2
3
6
5
4
7
ITEM
P/N
QTY
DESCRIPTION
1
77387
2
Machined Jaw
2
91622
2
Shell
3
62270DUB
2
Jaw Open Spring
4
91589
2
Push Rod
5
91588
2
Spring
6
91590
2
Push Rod Screw
7
91621
2
Spring Pin
IBC600 User Manual ◄ 21
92822 CRIMPING JAW ILLUSTRATION
1
1
2
2
3
6
5
7
22 ► IBC600 User Manual
ITEM
P/N
QTY
DESCRIPTION
1
91455
2
Machined Jaw
2
91622
2
Shell
3
62270DUB
2
Jaw Open Spring
4
91589
2
Push Rod
5
91588
2
Spring
6
91590
2
Push Rod Screw
7
91621
2
Spring Pin
4
92823 CRIMPING JAW ILLUSTRATION
1
1
2
2
3
6
5
4
7
8
9
11
10
ITEM
P/N
QTY DESCRIPTION
1
77389
2
Machined Jaw
2
91622
2
Shell
3
62270DUB
2
Jaw Open Spring
4
77418
2
Spring Cap
5
31224DUB
2
Spring
6
77416
2
Axis for Kearney Die
7
91590
2
Push Rod Screw
8
91588
2
Spring
9
91589
2
Push Rod
10
91621
2
Spring Pin
11
77417
2
Pin for Die Lock
IBC600 User Manual ◄ 23
STANLEY Infrastructure
6430 SE Lake Road
Portland, Oregon 97222 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyinfrastructure.com