JST BCT-8150 Manuel utilisateur

The Quality Connection

BCT-8150

HYDRAULIC CRIMPER

Instruction Manual

The Quality Connection

Table of Contents

1. Introduction………………………………………………………………………. 3

2. Specifications……………………………………………………………………. 3

3. Features………………………………………………………………………….. 4

4. Name of Components……..……………………………………………………. 4

5. Estimated Crimping Cycles…………………………………………………….. 4

6. Operation…………………………………………………………………………. 5

7. Precautions……..…………………………………………………………………9

8. Maintenance………………………………………………………………………10

9. Troubleshooting……….………………………………………………………… 11

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1. Introduction

The BCT-8150 is a battery operated 12 ton hydraulic crimping tool. Mechanism of this

tool is very simple. Manual pumping is replaced by a reciprocating motion driven by DC

motor using cam action.

2. Specifications

Crimping Tool BCT-8150

Output: 12 tons

Applicable range: Nominal size 8~150

Motor: 14.4V DC

Dimensions: 370 L x270 H x90 W

Weight: 5.2kg(11.44lbs)

Battery Cartridge BP-70MH

Type of Battery: NI-CD enclosed cylinder type

Output: DC14.4 V

Capacity: 1.2AH

Charging Time: 1 hour

Dimensions: 100 L x137 H x70 W

Weight: 0.73kg(1.61lbs)

Battery Charger CH-35R

Input: 120VAC 60hz

Charging Time: 1 hour

Dimensions: 195L x 95 H x 110 W

Weight: 1.9kg(4.18lbs)

Standard Accessories

Battery Pack: BP-70MH (2 cartridges)

Battery Charger: CH-35R

Dies: 8~150 nominal size

Carrying Case

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3. Features

1. Automatic self contained power tool.

2. Removable battery cartridge. Change cartridge for continuous operation.

3. One hand operation. One hand controls ram advancement and retraction.

4. No physical effort required for crimping. No pumping action required.

4. Name of Components

LED Indicator

Battery Cartridge

Operation/Release Trigger

Slide Pin Fluid Fill Cap

Cylinder Head

5. Estimated Crimping Cycles

The average number of crimping cycles of a fully charged battery are listed below. Crimping

cycles may vary due to various charging conditions. Number of cycles below are

approximate and for reference only. When crimping cycles of a fully charged battery

cartridge approaches half of the cycles indicated below, the battery cartridge should be

replaced soon. Battery recharging can be repeated approximately 500 times before needing

to be replaced.

Nominal Size Crimps per Charge

8 110

14 90

22 70

38 70

60 50

70 50

80 50

100 40

150 30

When the LED indicator on the tool lights up the battery needs to be recharged. After the LED

indicator stays on the tool will only operate another 5~10 times depending on conductor size

and battery conditions. The indicator may light up momentarily when the trigger is press. This

is normal and should be disregarded. Charge the battery only when thee indicator stays on.

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6. Operation

Charging

Cavity

1. Insert the AC plug of the battery charger into a wall outlet.

LED Indicator

CAUTION: MAKE SURE THE INPUT VOLTAGE IS 120VAC.

IF THE VOLTAGE SUPPLIED IS MORE THAN 130VAC THE

CHARGER AND THE BATTERY CARTRIDGE MAY BE

DAMAGED.

2. Insert the battery cartridge into the cavity of the charger.

CAUTION: KEEP THE CAVITY OF THE BATTERY CHARGER

FREE OF FOREIGN MATERIALS, ESPECIALLY METAL

OBJECTS.

Battery Cartridge

3. Time needed for a full recharge is 1 hour. The LED indicator

will be green when charging and turn orange when charging

is complete.

CAUTION: BE SURE TO FULLY RECHARGE THE BATTERY

WHEN THE TOOL IS DELIVERED OR AFTER A LONG TIME

OF STORAGE. IT IS RECOMMENDED TO FULLY

DISCHARGE THE BATTERY BEFORE RECHARGING.

Battery Cartridge

1. Depress the latch on the battery when detaching.

2. Slide the battery into the tool to install. Be sure the battery

is fully inserted and securely latches.

Latch

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Selection of Proper Dies

Female Die Male Die

Applicable Nominal Applicable Female

Die Male Die

Terminals Size Wire Range

(mm sq.)

8 6.64~10.52

TD-221 TD-211

Non-insulated 14 10.52~16.78 TD-222 TD-211

Terminals and 22 16.78~26.66 TD-223 TD-212

Splices 38 26.66~42.42 TD-224 TD-212

(Butt type, 60 42.42~60.57 TD-225 TD-213

Parallel type) 70 60.57~76.28 TD-226 TD-213

80 76.28~96.3 TD-227 TD-214

100 96.3~117.2 TD-228 TD-214

150 117.2~152.05 TD-229 TD-215

Note: Applicable wire range for parallel type non-insulated slices denotes the

total cross sectional areas of the wires to be used.

1. Choose the correct terminal and wire combination.

2. Choose the correct male and female dies from the chart above to match the nominal size

terminal to be used. The dies are clearly marked with the die number.

CAUTION: SELECTING THE WRONG COMBINATION OF DIES COULD DAMAGE THE

DIES OR THE TOOL ITSELF.

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Mounting dies

Slide Pin

1. Retract the piston by depressing the release trigger on

the main body of the tool.

Piston

2. Pull the slide pin out to open the crimp head.

3. With the crimp head open insert the female die until it is

locked into place by the ball plungers.

Female Die

4. Fully insert the male die into the piston.

Male Die

5. Close the crimp head and replace the slide pin.

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Preparing Wire To Crimp

1. Strip the wire insulation per the specifications below.

Terminal

Butt-type splices

Parallel-type splices

Crimping

1. Insert the terminal into the female die with the brazed seem

facing the male die.

2. Depress the operation trigger and advance the piston until

the dies are holding the terminal.

3. Insert the conductor into the terminal.

4. Depress the operation trigger until the piston has fully

extended and crimping is complete. A clicking sound is heard

when crimping is complete.

5. Depress the release trigger to retract the piston. Hold it until

the piston has completely retracted.

6. Pull the slide pin out and open the crimp head to remove the

crimped terminal.

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7. Precautions

Crimping Tool

1. Be sure to select the appropriate dies for the terminal to be crimped.

2. Never operate the tool without dies mounted and a terminal being crimped.

3. If the tool is stored at a cold temperature for an extended time, it is advisable to return to

room temperature for 1 hour before using.

4. Avoid dropping the tool. Excessive shock may damage the hydraulic circuit causing the

tool to malfunction.

5. Keep the cylinder head and piston clean and free of debris. Solvent can be used on the

head but should not be used on the plastic body.

Battery Cartridge

1. Never short circuit the battery terminals.

2. Avoid getting water, oil, or solvent near the battery.

3. Never disassemble or modify the battery.

4. Avoid dropping the battery cartridge.

5. Never store the battery at above 60 degrees Celsius for a long period of time.

6. Replace the battery cartridge when the crimping cycles are reduced to half of the cycles

indicated in the estimated crimping cycles section.

7. Never dispose of the battery cartridge in a fire.

8. The battery cartridge self discharges over time. It is recommended to charge the battery at

least every 3 months if the tool is not regularly used.

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Battery Charger

1. Never use the charger to charge other appliances.

2. Charger should be operated at 10~35 degrees C (50~95 degrees F).

3. Normal charging time is 1 hour. When charging several batteries, wait 15 minutes between

charging.

4. Never short circuit the output terminals.

5. Avoid water, oil, or solvent.

6. Never disassemble or modify.

7. Avoid dropping.

8. Maintenance

1. Daily maintenance is important to keep the tool in good working condition.

2. When storing the tool, avoid humidity.

Oil Reservoir

3. If air is trapped in the hydraulic circuit the piston will not move

back and forth smoothly. To replenish the oil remove the reservoir

cap and fill. Be sure to remove the battery and stand the tool on end

as shown to prevent the oil from spilling. Be sure to use Shell Tellus

T15 or equivalent.

4. Change the hydraulic fluid every 24 months. Approximately 120cc

of fluid is needed. When changing the oil be sure not to let air or dust

get mixed in the oil.

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