Instruction
Manual
EK
120/42
page
8
__________________________________________________________________________________________________________________
Table 2
(see Picture 3, page 2)
Marking
Crimping
range
mm²
Crimping
dies
outside profile
Surface of
the dies
16-400
TCL and C.
Standard
Version
CU,
„QS“
„QS“ chrome
plated
(yellow)
16-300
TCL and C.
DIN 46235
DIN 46267
CU, QS
DIN
46235
code # chrome
plated
10-240 Aluminium
CL and C.
AL, „QS“ code # blue zinc
25-185 Aluminium
C. Aldrey
Al, „QS“ code # blue zinc
Al, „QS“ code # blue zinc
25/4-
120/20
Full tension
C. DIN
48085 T3
ST, „QS“ code # black
10-240
sm
35-300 se
Pre-rounding
dies
RU;
QS, sm;
QS, sm
- chrome
plated
16-150 Terminals
DIN 46234
DIN 46230
CU, QS
DIN
46234
„QS“ chrome
plated
10-95 insulated
terminals
ISQ, QS
„QS“
chrome
plated,
16-150
tub. CL for
fine-str.
conductors
F, QS
„QS“
chrome
plated
4-70 C-clamps C,
QS -
chrome
plated
10-150 pre-insulated
tub. CL and
connectors
IS, QS
„QS“
chrome
plated
2x50-
2x95
double com-
pression CL
DP, QS
„QS“
chrome
plated
25-240
WF
AE, QS
-
chrome
plated
25-240 WF
for
comp. fine
str. cables
AE, QS
-
chrome
plated
A b b r e v i a t i o n s : T C L - T u b u l a r c a b l e l u g s , C - C o n n e c t o r s , W F -
W i r e F e r r u l e s , Q S - C r o s s - s e c t i o n
Attention
Do only crimp those connecting materials
mentioned in Tab. 2
If different conducting materials have to be crimped, please
contact the manufacturer.
Attention
Do not crimp on live cables or conductors
The EK 120/42 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.
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
3
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
sophisticated electronics 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.
As soon as the speed of the machine decreases noticeably the
battery must be recharged. Do not recharge a partially empty battery
as a precaution.
If charging a battery which has currently been used or which was
laying in the sun for a longer period of time the LED might flash
red. In this case wait for a while. The charging procedure starts after
the battery cooled down.
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.
