Instruction
Manual
EK60G5INS
page
7
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5. Remarks in respect of the determined use
Before starting any work on electrical appliances it must be
safeguarded that there are no live parts in the immediate assembly
area of the user. Is this not possible special precaution measures
1
for working near live parts must be provided.
Prior to operating the unit the charging level of the battery (Pos.-
No. 7) should have been tested
2
. A low charging level can be
detected by the flashing of the LED (Pos.-No. 6) for 20 s at the end
of a crimping cycle.
5.1. Operation of the unit
First you have to select the right dies (Pos.-No. 10) for the
intended application.
Attention
Don’t operate the tool without dies.
Afterwards the dies will be inserted into the crimping head while
actuating the die locks (Picture 3 Pos.-No.3). After releasing the
die locks the dies stay in place.
The crimping procedure is initiated by actuating the trigger (Pos.-
No. 1 & Picture 2 Pos. A). The crimping process is defined by the
closing motion of the dies. During that process the connecting
material is positioned in the stationary half of the die whereas the
moving part of the die is approaching the compression point
3
.
The crimping process is terminated when the crimping force is
reached. After having completed the crimp the dies return into the
starting position automatically.
Attention
After having terminated the crimping
process and prior to changing the dies
remove the battery to avoid unintended use.
In case of error or emergency the dies can be returned into the
starting position by actuating the retract button (Pos.-No. 2 &
Picture 2 Pos. B).
Attention
The crimping process can be interrupted at any
moment by releasing the trigger.
5.2. Explanation of the application range
The EK 60G5INS has a large number of various dies (Pos.-No. 10)
available to crimp connecting materials from copper or
Aluminium.
Attention
Do not crimp on live cables or conductors
The insulated crimping head constitutes a protection against
accidental contacts of neighbouring live lines. In addition it
prevents a possible flash-over from neighbouring live lines.
This protection does not substitute necessary special precaution
measures
1
for working near live lines.
The EK 60G5INS is a hand held tool and it is not supposed to be
restrained in a vise. It is not allowed to use the tool in a stationary
application.
The tool is not designed for continued crimping operations. After a
sequence of approximately 30-40 completed crimps you have to
make a break of 15 min. to give the tool time to cool down.
1
See EN 50110-1
2
See Chapter 5.5 for more information of the battery and charging unit
3
See picture 4 page 2
Attention
Too intensive use can cause heat damages for the tool
Attention
During the operation of electric engines sparks can occur
which might ignite highly inflammable or explosive
liquids and materials
Attention
Electric-hydraulic crimping tools should not be operated
in pouring rain or under water.
5.3. Mounting instructions
Please read the assembly instructions in Chapter 12 of our general
catalogue.
Attention
Even if the code number is identical only those dies
should be used which are suitable for the material.
Please use the following assembly instructions for cable lugs and
connectors:
1. Strip the conductor according to insertion depth (+10% due to the
change of length of the crimped sleeve)
2. The Conductor ends must be cleaned with a cloth or brush before the
assembly.
3. Insert the conductor fully into the cable lug or connector
4. Pay attention to the crimping directions and use the appropriate dies.
The crimping directions
4
for cable lugs and connectors is indicated in
the illustration below.
5. After crimping, wipe away excess compound forced out of Al-cable
lugs and connectors.
5.4 Service and maintenance instruction
The electric-hydraulic crimping unit is equipped with a controller
enabling the user to see when the next service is due. (Pls. read chapter
4.3 for more information) When the next service is due the unit must to
be returned to an authorised service center.
For every day service the unit has to be cleaned and dried after each use.
The battery cartridge (Pos.-No. 7) and the charging unit have to be
protected against humidity and dust.
Within the determined use of the tool only the dies (Pos.-No. 10) are
permitted to be changed by the customers.
Attention
Do not damage the seals of the tool.
If the seals are damaged the warranty is invalidated.
5.5 Remarks on the use of the battery cartridge and charging unit
.
The charging unit is run with a nominal voltage of 230 V and a
frequency of 50-60 Hz. New batteries must be charged prior to use. To
charge the battery cartridge (Pos.-No. 7) the power plug of the charging
unit has to be plugged into the power supply and the battery cartridge
has to be pushed into the charging unit. The charging time is one hour.
The charging level of the battery cartridge can be checked by a LED
5
.
green
battery cartridge is charged
red
Battery cartridge is empty and is just being charged
flashing battery cartridge is not pushed in properly or too hot,
a sound signal occurs
Is the battery plugged in correctly the LED changes from green to red
and the charging procedure starts. When the charging procedure is
terminated the LED changes again to green. Simultaneously a signal
occurs for 5 seconds.
No other battery cartridges e.g. dry batteries or car batteries etc. are
permitted to be used neither in the tool nor in the charging unit.
4
See Picture 4 on Page 2
5
The charging level of the battery can also be verified by the LED of the
tool at the end of a crimping cycle. See chapter 4.3 for further information.