IBC600 6-TON IN-LINE CRIMPING TOOL USER MANUAL Safety, Operation and Maintenance 07 STANLEY Black & Decker, Inc. New Britain, CT 06053 U.S.A. 840 /08 Ver.
TABLE OF CONTENTS SAFETY SYMBOLS...4 SAFETY PRECAUTIONS...5 TOOL ANATOMY...6 SPECIFICATIONS & ACCESSORIES...7 OPERATION...8 STANLEY CRIMP SOFTWARE... TROUBLESHOOTING...6 IBC600 PARTS ILLUSTRATION...7 IBC600 PARTS LIST...8 IBC600 HYDRAULIC BODY ILLUSTRATION...9 IBC600 HEAD UNIT ILLUSTRATION...0 98 CRIMPING JAW ILLUSTRATION... 98 CRIMPING JAW ILLUSTRATION... 983 CRIMPING JAW ILLUSTRATION...3 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. Keep these instructions in an area accessible to the operator and maintenance personnel. 4 IBC600 User Manual
SAFETY PRECAUTIONS Tool operators must comply with precautions given in this manual and on the stickers attached to the tool. These precautions are given for your safety. Review them carefully before operating the tool. 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 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. Never wear loose clothing that can become entangled in the working parts of the tool. 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. 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. Do not use the tool, battery or battery charger for purposes other than what is described in this manual. 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. 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 65 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:. Wash quickly with soap and water.. If the liquid gets in your eyes, flush your eyes with clean water for 0 minutes. Seek medical attention immediately. Never open the battery. BATTERY CHARGER Do not use the battery charger if the cord is damaged. Do not place the charger, or set items on or near the charger, in such a way as to block airflow to the charger. 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. Length of Cord (Feet) 5 50 00 50 Wire Size (AWG) 8 8 8 6 Table : 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
WHAT IS THE IBC600? TOOL ANATOMY 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. Crushing Risk Decal Crimping Jaws 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 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 0V Max ( Amp/hour or 5 Amp/hour) Estimated Crimps per Charge... 00 ( Amp/hour), 450 (5 Amp/hour) Tool Weight with Amp/hour battery... 7.5 Lbs. with 5 Amp/hour battery... 7.70 Lbs. Tool Length...8.8 Inches ( Amp/hour batt.) 9.6 Inches (5 Amp/hour batt.) Maintenance Interval...Every 30,000 Cycles ACCESSORIES SPECIFICATIONS & ACCESSORIES D3/O Jaw...98 (Accepts standard W dies) D3/BG Jaw...98 (Accepts standard W dies) Kearney/BG Jaw...983 (Accepts Kearney and W dies) Amp/hour DeWalt 0V Max Battery... DCB03 5 Amp/hour DeWalt 0V Max Battery... DCB05 5 Amp/hour DeWalt 0V Max Battery -pack... DCB05-0V AC Charger...DCB5 V DC Charger...DCB9 Note: Only use battery chargers recommended by STANLEY. Bucket Bag... BB0 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. Pull back the pin lock to eject the jaw pin.. Insert the crimping jaw and lock the jaw pin. 3. Insert the battery pack. 8 IBC600 User Manual
OPERATION CRIMPING. Set the Trigger Lock 4 5 Set the trigger lock BEFORE attaching dies to the jaw!. Clip the die onto the Crimping Jaw. Figure : 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 White Green Red Meaning Crimping. InteLED will stay lit for 30 seconds after a crimp is complete. The crimp is good. IBC600 did not reach full pressure. Crimp again. IBC600 User Manual 9
OPERATION CHECKING BATTERY CHARGE Battery Check Button 75-00% Charged 5-74% Charged Less than 50% Charged Charge Battery SECURE THE JAWS INTO PLACE (OPTIONAL) 3 Jaw Coupling 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.. Set the trigger lock and insert the jaws.. Lock the jaw pin into place. 3. Insert the pin and set screw to lock the jaw pin. 0 IBC600 User Manual
OPERATION STANLEY CRIMP SOFTWARE STANLEY Crimp software provides valuable data about each crimp. It is also required to update the tool firmware. INSTALLATION. 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.. Follow the prompts to complete installation. 3. Connect IBC600 to a PC using a micro USB cable. Note: InteLED will shine blue when connected. FIRST RUN. Run the software using the STANLEY Crimp software icon on your Windows desktop.. 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. IBC600 USB Connection USER SELECTION. Click the New User button.. Enter the required user information and click Create. 3. Select a user and click OK. IBC600 User Manual
OPERATION TOOL INFORMATION The Tool Information tab displays important data about the IBC600.. Displays the product type, serial number and firmware version of the tool.. Basic data relating to the life and service interval of the tool. TOOL USAGE DATA 3 IBC600 User Manual
OPERATION The Tool Usage Data tab displays information about individual tool cycles.. Displays the total number of tool cycles, as well as completed and non-complete cycles.. The data log shows each cycle, up to 50,000 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 IBC600 User Manual 3
OPERATION The Worksite Reports tab allows you to group data log entries into a complete tool cycle report. 4 3 5. Click Create Report.. 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. 4 IBC600 User Manual
OPERATION AVAILABLE UPDATES The Available Updates tab will allow you to update the tool firmware and update STANLEY Crimp software.. Tool Firmware Update button. When clicked, this will begin to tool firmware update process. Do not unplug the tool during this process.. Software Update button. When clicked, this will update the STANLEY Crimp software, if an update is available. IBC600 User Manual 5
TROUBLESHOOTING Problem I can t install the crimping jaw / The crimping jaw doesn t fit into the tool body. The jaw pin won t fit through the hole in the crimping jaw. The jaw pin wont spring back, even though I am pulling back on the pin lock. The tool won t crimp when I press the trigger. The InteLED flashes yellow when I activate the tool. The tool repeatedly gives me bad crimps / The InteLED flashes red after every crimp. The tool will not release pressure when the pressure release is held. The tool is leaking hydraulic oil. The tool cannot connect to STANLEY Crimp software. The tool is not saving crimp data. Solution Press and hold the pressure release to fully retract the piston. Insert the jaw into the tool body. Remove the crimping jaw. Ensure the two halves of the crimping jaw are aligned. Ensure that the jaw locking hardware is removed (see page 0). Press and hold the pressure release to fully retract the piston. Pull back on the pin lock to eject the jaw pin. Ensure the battery is charged. Disengage the trigger lock. The maintenance interval is about to elapse. Have the tool serviced as soon as possible. Ensure the battery is fully charged. Ensure the crimping jaw is properly installed and the die is properly attached. If problem persists, have the tool serviced as soon as possible. Have the tool serviced immediately. Have the tool serviced immediately. 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. Have the tool serviced as soon as possible. 6 IBC600 User Manual
97 66 4 00 0 0 65 44 99 64 50 7 7 75 63 56 34 5 4 40 4 63 57 05 08 53 86 47 78 4 50 67 0 76 69 68 8 78 75 86 5 06 36 3 44 07 IBC600 PARTS ILLUSTRATION IBC600 User Manual 7
IBC600 PARTS LIST ITEM P/N QTY DESCRIPTION 4 64DUB Compression Spring 3 77058 Shackle (Torque to Nm) 4 940 USB Cover 34 9585 Oil Tank 40 9586 Oil Tank Plug 4 ZBINA405 Magnet Pin 4 966 Metal Clamp 44 96 Housing Set 47 J4450300X70 O-Ring 44.5 x 3 50 9878 Electronic Device 5 AIG.5x7.8BR Calibrated Pin 63 967 Metal Clamp 67 AAIN0 Circlip 68 JSR004 Lip Seal 69 JBS04.5 Sealing Washer 75 VAV03HC006 Screw 76 VAV04CB006 4 Screw (Torque to Nm) 78 VAV04FH006 6 Screw (Torque to Nm) 8 VAV3.5TC04ZN 7 Screw 86 963 Membrane Support 00 64DUB Compression Spring 03 77070 Cam Holder 05 9647 STANLEY Logo Decal 06 9648 IBC600 Decal 07 9634 Powered by DeWalt Right Decal 08 9635 Powered by DeWalt Left Decal 09 9637 INTELED Left Decal 0 9636 INTELED Right Decal 77067 Cam 3 RBAM6 Pin Stop 36 9465 Strap Ring 5 9833 Motor and Gearbox Assembly ITEM P/N QTY DESCRIPTION 53 See page 9 Hydraulic Body Assembly 56 See page 0 Head Unit 57 9877 Outer Trigger Assembly 64 70884DUB Roller Assembly 65 7547 Piston 66 9603 Guiding Ring (Torque to 5 Nm) 8 IBC600 User Manual
IBC600 HYDRAULIC BODY ILLUSTRATION 65 5 8 56 7 6 35 6 6 54 48 5 40 55 5 6 60 63 ITEM P/N QTY DESCRIPTION 6 338DUB Spring 8 7786 Cam Roller 5 77065 Cam Box 7 9606 Release Lever 35 77086 Spring 40 9584 Hydraulic Body 48 77504 Spring 5 AIG.5X3.8BR Pin 55 AIG4X3.8BP Calibrated Pin 56 AIG4X9.8BP Calibrated Pin 65 J30000 O-Ring 3 x 60 77805-0 Delivery Valve Unit 6 77076 Cross Head 6 77837 Pressure release valve (Torque to 6 Nm) 63 77806-0 Succion Valve Unit (Torque to Nm) 54 9875- Valve Unit (Torque to Nm) IBC600 User Manual 9
IBC600 HEAD UNIT ILLUSTRATION 5 9 0 8 7 5 5 3 4 8 6 3 4 0 IBC600 User Manual ITEM P/N QTY DESCRIPTION 77035-0 Toothed Wheel 77394 Axis for jaws set 3 78476-0 Pull Tab 4 78586 Spring 5 8405DUB Spring 6 9437 Plug 7 9440 Spacer Tube 8 959 Half Flange 9 AIG.5X7.8BR Calibrated pin 0 AIG3x.8BP Calibrated Pin AIG3.5x3.8BR Calibrated Pin VAV04BT006FF Screw 3 VAV04EB00 Screw 4 VAV04CB05 Screw 5 VAV04HC00 4 Screw
98 CRIMPING JAW ILLUSTRATION 3 6 5 4 7 ITEM P/N QTY DESCRIPTION 77387 Machined Jaw 96 Shell 3 670DUB Jaw Open Spring 4 9589 Push Rod 5 9588 Spring 6 9590 Push Rod Screw 7 96 Spring Pin IBC600 User Manual
98 CRIMPING JAW ILLUSTRATION 3 6 5 4 7 ITEM P/N QTY DESCRIPTION 9455 Machined Jaw 96 Shell 3 670DUB Jaw Open Spring 4 9589 Push Rod 5 9588 Spring 6 9590 Push Rod Screw 7 96 Spring Pin IBC600 User Manual
983 CRIMPING JAW ILLUSTRATION 3 6 5 4 7 8 9 0 ITEM P/N QTY DESCRIPTION 77389 Machined Jaw 96 Shell 3 670DUB Jaw Open Spring 4 7748 Spring Cap 5 34DUB Spring 6 7746 Axis for Kearney Die 7 9590 Push Rod Screw 8 9588 Spring 9 9589 Push Rod 0 96 Spring Pin 7747 Pin for Die Lock IBC600 User Manual 3
STANLEY Infrastructure 6430 SE Lake Road Portland, Oregon 97 USA (503) 659-5660 / Fax (503) 65-780 www.stanleyinfrastructure.com