4 M 68 U ENGLISH Certified Quality Management System Certified Environmental Management System Certified Occupational Health & Safety Management System BATTERY OPERATED HYDRAULIC CRIMPING TOOL B54M-D6A B54M-D6-8A B54M-KA OPERATION AND MAINTENANCE MANUAL
WARNING LABELS Tool Before using the tool, carefully read the instructions in this manual. When operating the tool, keep hands away from the danger zone. See page 0. Battery Never throw batteries into fire or water. Always recycle the batteries. Do not discard batteries into domestic refuse or waste disposal.
FIG. B54M-D6A with D groove to accept all "W" style crimping dies + "BG" fixed groove B54M-D6-8A with D groove to accept all "W" style crimping dies + "O" fixed groove B54M-KA with groove to accept all "O" style Kearny crimping dies. Adapter to accept all "W" style crimping dies available as an accessory
BATTERY OPERATED HYDRAULIC CRIMPING TOOL. GENERAL CHARACTERISTICS Application range: TOOL TYPE: Crimping force kn (sh ton): Rated operating pressure bar (psi): Dimensions LxWxH mm (inches): Weight with battery kg (lbs): Motor Volt DC: Battery type CB80L Volt / Ah: Recommended oil: Safety: Operating temperature C ( F): Types of jaw supplied: (see table A page 0 for compatibility) Battery charger ASC0-6 USA/CAN 7046000 Input Volt / Hz: 5 / 60 W: 85 Acoustic Noise (Directive 006/4/EC, annexe, point.7.4. letter u) The weighted continuous acoustic pressure level equivalent A at the work place L pa is equal to... 64,9 db (A) The maximum value of the weighted acoustic displacement pressure C at the work place L pcpeak is equal to... 99,7 db (C) The acoustic power level emitted by the machine L WA is equal to... 69, db (A) Risks due to vibration (Directive 006/4/EC, annexe, point...) Tests carried out in compliance with the indications contained in UNI ENV 549 and UNI EN 866 part st Standards, and under operating conditions much more severe than those normally found, certify that the weighted root mean square in frequency of the acceleration the upper limbs are exposed to for each biodynamic reference axis is 0,57 m/sec max. The part reference includes the following: Basic tool complete with battery. Spare battery. Battery charger (model depends on the tool version). Plastic carrying case. B54M-D6A B54M-D6-8A B54M-KA suitable for installing electrical compression connectors for conductors up to 50 mm (00 MCM) 54 (6) 40 (4,900) 445 x x 8 458 x x 8 (8 x 5. x.) (7.5 x 5. x.),95 (6.5),0 (6.6) 8 8 /.0 Li-Ion AGIP ARNICA or ESSO INVAROL EP or equivalent. the tool is equipped with a maximum pressure valve. -5 to +50 (+5 to +) CDD 6 with D groove to accept all "W" style crimping dies + "BG" fixed groove CDD 6-8 with D groove to accept all "W" style crimping dies + "O" fixed groove CDK with groove to accept all "O" style Kearny crimping dies 4
. INSTRUCTIONS FOR USE The tool is equipped with automatic return of the dies once the crimping operation is completed. The interchangeable crimping jaws have thermoplastic rubber covers on outside edges. Residual battery capacity level is automatically displayed after every cycle. The part reference B54... includes the following: Basic tool complete with battery Spare battery Battery charger Canvas bag..) Preparation With the tool in the rest position (the ram fully retracted) proceed as follows: Select the appropriate groove or die set for the connector to be crimped. Insert the dies into the jaws of the tool (see.8). Insert the conductor into the connector..) Die advancement (Ref. to Fig. ) Grip the tool firmly and comfortably. Position the connector in the die groove and ensure the correct location of the crimp. Press operating button (4) to activate the motor-pump group for the advancement of the ram. To halt the advancement, release the operating button and the motor will cut out. 9 Make sure the dies are exactly positioned on the desired crimp point otherwise re-open dies following instructions as per.5 and reposition the connector. 4 FIG. 5
.) Compression Insert the conductor in the connector and press the operating button (4): the ram will gradually move forward until the two dies touch. It is recommended to keep operating until the maximum pressure valve is activated and a "click" is heard, after which the dies will automatically re-open until the ram is fully retracted. It is always possible to interrupt automatic retraction of the ram by a short push on the operating button (4)..4) Head rotation For ease of operation the tool head can rotate through 80, allowing the operator to work in the most comfortable position. Warning: do not attempt to rotate the head when the hydraulic circuit is pressurised..5) Release of dies Press the pressure release button (9), the ram will retract and open the jaws..6) Battery status (Ref. to Fig. ) The battery is equipped with LED indicators that indicate the remaining battery life at any time by pressing the adjacent button (P). 4 LEDs illuminated: Fully charged LEDs illuminated: 50 % capacity LED flashing: Minimum charge, replace the battery P FIG..7) Insertion/replacement of battery To replace the battery, remove it by pressing the release button (5) (Ref. to Fig. 4), then insert the new battery, sliding it into the guides until it locks. 5 FIG. 4 6
.8) Crimping die assembles.8.) Use of W style crimping dies (B54M-D6A, B54M-D6-8A tools) Press pins () and insert W dies into their seats (see Fig. 5A). To disassemble them simply press the pins and slip them from the jaws..8.) Use of O style Kearney crimping dies (B54M-KA tool) Insert O dies into their seats, the two dies will be held by the retainers (7) (see Fig. 5B). To disassemble them simply slip them from the jaws. Note: it is possible to use W style crimping dies with B54M-KA by means of the AU55-B adapter, available as an accessory. IT IS RECOMMENDED TO USE THE TOOL ONLY WITH PRODUCT TO BE CRIMPED INSERTED. "W" style crimping dies "O" style crimping dies 7 7 FIG. 5A B54M-D6A, B54M-D6-8A tools FIG. 5B B54M-KA tool 7
.9) Jaw replacement Each tool is supplied with relevant jaws (see ). Jaws can also be supplied separately, for replacement proceed as follows: Push and turn clockwise the locking pin (9) so that the jaws are released. Slide the jaws out of the top of the tool and insert the new ones (see Fig. 6). Fully insert the locking pin (9) into the tool and lock it by turning clockwise until the red lines are aligned. red lines FIG. 6 9. WARNING Before starting work on electrical equipment, please ensure that either there are no live parts in the immediate working area or that precautions are taken for working near live parts in accordance with EN500-. DO NOT USE THIS TOOL ON OR NEAR ENERGISED CONDUCTORS WITHOUT PROPER PERSONAL PROTECTIVE EQUIPMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN SEVERE INJURY OR DEATH. THE TOOL IS UNSUITABLE FOR CONTINUOUS USE AND SHOULD BE ALLOWED TO COOL DOWN FOLLOWING UNINTERRUPTED, SUCCESSIVE CRIMPING OPERATIONS; FOR INSTANCE, HAVING EXHAUSTED A FULLY CHARGED BATTERY IN ONE SESSION, DELAY BATTERY REPLACEMENT FOR A FEW MINUTES. OBSERVE RECOMMENDED REST PERIODS ALSO WHEN USING AN EXTERNAL POWER SUPPLY. PROTECT THE TOOL FROM RAIN AND MOISTURE. WATER WILL DAMAGE THE TOOL AND BATTERY. ELECTRO-HYDRAULIC TOOLS SHOULD NOT BE OPERATED IN POURING RAIN OR UNDER WATER. 8
.) Using the battery charger Carefully follow the instructions in the battery charger manual. 4. MAINTENANCE The tool is robust, completely sealed and requires very little daily maintenance. Compliance with the following points should help to maintain the optimum performance of the tool: 4.) Thorough cleaning Dust, sand and dirt are a danger for any hydraulic device. Every day, after use, the tool must be wiped with a clean cloth taking care to remove any residue, especially close to moveable parts. 4.) Storage When not in use, the tool and accesories should be stored and transported in the relevant canvas bag to prevent damage. 9
TABLE A INTERCHANGEABLE CRIMPING JAWS JAW TYPE GROOVES CRIMPING DIE COMPATIBILITY FCI Burndy W, X Series CDD6 D TO ACCEPT ALL W STYLE CRIMPING DIES + BG FIXED GROOVE Greenlee KD6 Series Ilsco ND Series CDD6-8 D TO ACCEPT ALL W STYLE CRIMPING DIES + O FIXED GROOVE Huskie Panduit HT-58 Series CD-00 series FCI Burndy W, X Series Greenlee KD6 Series CDK GROOVE TO ACCEPT ALL O STYLE KEARNEY CRIMPING DIES AU55-B ADAPTER TO ACCEPT ALL W STYLE CRIMPING DIES AVAILABLE AS AN ACCESSORY Ilsco Huskie Panduit ND Series HT-58 Series CD-00 Series Kearney O Series Blackburn 6 tons - Following information applies in member states of the European Union: USER INFORMATION in accordance with Directives 00/95/EC and 00/96/EC regarding the reduction of hazardous substances in electrical and electronic equipment, including the disposal of waste. The 'Not in the bin' symbol above when shown on equipment or packaging means that the equipment must, at the end of its life, be disposed of separately from other waste. The separate waste collection of such equipment is organised and managed by the manufacturer. Users wishing to dispose of such equipment must contact the manufacturer and follow the prescribed guidelines for its separate collection. Appropriate waste separation, collection, environmentally compatible treatment and disposal is intended to reduce harmful environmental effects and promote the reuse and recycling of materials contained in the equipment. Unlawful disposal of such equipment will be subject to the application of administrative sanctions provided by current legislation. 0
5. RETURN TO Cembre FOR OVERHAUL In the case of a breakdown contact our Area Agent who will advise you on the problem and give you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible, attach a copy of the Test Certificate supplied by Cembre together with the tool or, if no other references are available, indicate the approximate purchase date and the tool serial number. SPARE PARTS LIST The guarantee is void if parts used are not Cembre original spares. When ordering spare parts always specify the following: - code number of item - name of item - type of tool - serial number of tool TABLE Code N Item DESCRIPTION Qty 6000577 BODY RIGHT+LEFT SHELL 60008 BATTERY ADAPTER SHELL R+L 598495 BATTERY CB80L Li-Ion 8V Ah 60007 4 OPERATING BUTTON 60007 5 SHUTTER 600059 6 ROD 600059 7 SPRING 600050 8 CONTACT SUPPORT 60008 9 PRESSURE RELEASE BUTTON 600058 0 BUTTON STRIKER 600655 MECHANICAL GROUP 600468 COMPLETE ELECTRICAL CIRCUIT 60006 SHUTTER 6000589 4 WRIST STRAP 600680 5 BATTERY RELEASE 6900650 6,5X6 SCREW 8 6505 7 SPRING 6746 8 TG.0990 LABEL 6500 9 TG.0704 LABEL 6676 0 TG.099 LABEL
See TABLE 4 7 9 6 0
8 TABLE 0 9 6 5 0 8 5 7 4
TABLE (ITEM IN TABLE ) Code N Item DESCRIPTION Qty 600065 90 RUBBER GRIP 600099 00 ACTUATING MECHANICAL GROUP 600057 00 HOUSING 600058 00 4 GEAR 6760004 00 8 Ø X8 CYLINDRICAL PIN 6900008 00 9 Mx6 SCREW 6000849 00 0 Ø SCHNORR WASHER 674000 00 /4" BALL 60006 00 5 GEAR 640009 00 6 BEARING 640006 00 7 WASHER 60008 00 8 WASHER 67600 00 9 CYLINDRICAL PIN 60005 00 0 SPACER 6000 00 0 COMPLETE DISC 60009 00 6 DISC 60007 00 7 BALLS SUPPORT 6700080 00 8 Ø 6 CIRCLIP 66506 00 9 WASHER 6000 00 0 COMPLETE CAM 600098 00 50 COMPLETE MOTOR 60005 00 COMPLETE HYDRAULIC GROUP 660 00 RAM 66098 00 SEAL 6000560 00 5 MEMBRANE RING 67007 00 6 OIL RESERVOIR 60007 00 7 VALVE PISTON 600056 00 8 GRUB SCREW 650 00 9 VALVE SPRING 66078 00 PUMPING RAM 600056 00 4 VALVE ROD 6000575 00 6 SPRING SUPPORT 6000565 00 7 TEST PRESSURE CAP 66407 00 0 WASHER 6000567 00 SETTING VALVE LOCKNUT 600060 00 45 PRESSURE RELEASE LEVER 6000570 00 57 PUMPING RAM RETURN SPRING 674000 00 6 5/" BALL 65060 00 6 SPRING 640590 00 64 GRUB SCREW 4
TABLE (ITEM IN TABLE ) 5
6 4 6 9 8 7 75 0 67 6 50 67 64 65 66 0 70 45 6 77 60 7 6 5 4 5 6 6 8 7 90 600 9 65 7 7 69 4 0 68 *
TABLE (ITEM ) 4 9 00 8 0 8 9 50 7 8 0 6 9 6 0 0 5 57 7 500 400 7 4 5 00 * TIGHTENING TORQUE COUPLE DE SERRAGE DREHMOMENT PAR DE TORSION COPPIA DI SERRAGGIO 8 Nm (5.9 lbf ft) 7
TABLE (JAW) Code N Item DESCRIPTION Qty 600060 600060 66000 66000 650404 650404 65060 65060 6807 6807 6760085 6760085 - - CDD6 CDD6-8 60006 66000 650404 65060 6807 6760085 640007 CDK 4 5 6 7 RUBBER COVER DIE RETAINER PIN SPRING SPRING M AUTOLOCK NUT Ø x ELASTIC PIN DIE RETAINER 5 6 4 5 CDD6 jaw 6 8
5 6 4 5 CDD6-8 jaw 6 5 7 7 4 6 5 CDK jaw 6 9
This manual is the property of Cembre: any reproduction is forbidden without written permission. Cembre S.p.A. Via Serenissima, 9 55 Brescia (Italia) Telefono: 00 69 Telefax: 00 65766 E-mail: sales@cembre.com www.cembre.it www.cembre.com Cembre Ltd. Dunton Park Kingsbury Road, Curdworth - Sutton Coldfield West Midlands B76 9EB (Great Britain) Tel.: 0675 470440 - Fax: 0675 4700 E-mail: sales@cembre.co.uk www.cembre.co.uk Cembre S.a.r.l. Avenue Ferdinand de Lesseps 940 Morangis (France) Tél.: 0 60 49 90 - Fax: 0 60 49 9 0 B.P. 7-94 Morangis Cédex E-mail: info@cembre.fr www.cembre.fr cod. 6698 Cembre España S.L. Calle Verano, 6 y 8 - P.I. Las Monjas 8850 Torrejón de Ardoz - Madrid (España) Teléfono: 9 485580 Telefax: 9 48558 E-mail: comercial@cembre.es www.cembre.es Cembre AS Fossnes Senter N-60 Stokke (Norway) Phone: (47) 6765 Telefax: (47) 6766 E-mail: sales@cembre.no www.cembre.no Cembre GmbH Heidemannstraße 66 8099 München (Deutschland) Telefon: 089/580676 Telefax: 089/5806777 E-mail: sales@cembre.de www.cembre.de Cembre Inc. Raritan Center Business Park 8 Fieldcrest Avenue Edison, New Jersey 0887 (USA) Tel.: (7) 5-745 - Fax: (7) 5-744 E-mail: Sales.US@cembreinc.com www.cembreinc.com0