haupa AO-6 User manual

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Electro hydraulic crimping tool
„AO-6“
INSTRUCTION MANUALHydraulic crimping tools
Video 216800

1. Technical characteristics
Area of application: For the creation of an electrical connection by means of compression
Pressing force: 60 kN
Scope of delivery: 1 crimping tool, 1 charger, 1 battery, 1 carry strap, in plastic case,
without dies
Oil type: ISO class viscosity 15
Feed rate: 2 speeds: Closing (fast) feed to bring the pressing dies to the conductor
and working feed for compression. Switching between the two speeds is
carried out automatically.
Safety: The tool is fitted with a safety value that has been set at the factory.
Structure: The working head can be rotated by 180° to make it easier to adapt to
the operation to be carried out. The model Art. 216800 does not protect
the operator when working on cables that carry power.
Guarantee: 2 year guarantee if used for the purpose it is intended
2. Area of work
• Pressing force in kN: 60
• Working pressure in bar: 700
• Opening/ Hub: 17 mm
• Head can be opened
• Pressing width: slim
• Motorstop
• Crimping range cable lugs: Cu 6-300 / DIN Cu 6-300 / DIN Al 16-240
• Crimping range connectors: Cu 6-300 / DIN Cu 6-300 / DIN Al 16-240
• Pressing time, battery-operated in seconds: 4
• Battery charging time in minutes: 120
• Battery type: Li-Ion, 18 V, 4 Ah
• Dual-piston pump
• Weight in kg: 4,5
• Weight of set in kg: 9,5
2.1. Sensor Technology
With the different colours of the sensor LED, it shows whether the pressing has
been completed successfully or which errors have occurred:
Light is green: Pressing completed as standard, motor stopped
Light is orange: Battery voltage not sufficient
Light is red: Pressing interrupted before completed
The device also has 2 white LED designed to illuminate the working area.

Germany: HAUPA GmbH & Co. KG, Königstraße 165-169, D-42853 Remscheid.
Phone: [phone], Fax: [phone], [email protected] • Errors and technical changes reserved.
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english
3. Operating instructions
CAUTION! TOOLS MAY NEVER BE USED WITHOUT FIRST INSERTING THE PRESSING DIES.
Ensure that the pressing dies fit precisely to the appropriate area and are seated perfectly in
the holders.
OTHERWISE THIS MAY CAUSE SERIOUS DAMAGES OR BREAKAGES AND THE GUARANTEE
WILL BE VOIDED.
Preparation:
Before starting up the tool, read the operating instructions first.
All current-carrying elements in the area you are working in should be disconnected.
Otherwise the protective procedures for working in the vicinity of components under current
must be implemented. (DIN EN 50110)
Do not use the tool if you are tired or under the influence of medication, drugs or alcohol.
Take into account the valid accident prevention and safety regulations and use the tool exclu-
sively for the purpose for which it is intended.
Only electro-technically trained persons over 16 years of age may process connecting materi-
als using the tool.
The operating instructions must always be carried with the tool.
The instructions must have been read and understood by the user.
The operator must ensure that this is the case.
Operating:
• Select the appropriate pressing dies for the connection to be pressed.
Die holder
Pushbutton
to advance
Pushbutton for
return movement

• Insert the pressing dies in the tool head. All of the pressing dies that can be used in
these models are half-circles, regardless of the type of crimping or pressing being
carried out. They are made up of two parts with identical external measurements, so that
they both can be inserted at will into the piston or the head.
• The procedure for inserting pressing dies is identical for mounting to both piston and
head.
• The dies are inserted via the guides until they come to a stop at the blocking pin.
• When inserting into the piston, you must only ensure that this is pushed far enough
forward for the release button to be visible and accessible.
Operating:
• To remove the dies, in both instances, the relevant release button must be activated.
Then allow the dies to slide out. Please note that in order to remove the inserts at the
piston, the steps listed above must be carried out in reverse order.
Start:
- Bring the tool to the working position.
- Select the appropriate pressing dies for the connection to be pressed.
- Insert the pressing dies in the tool head.
- Feed the conductor into the connector.
- Place the connector between the two pressing dies.
- Approach of the pressing dies (closing feed rate)
- Hold the tool securely and press the operating button to move the piston quickly
forwards until the pressing dies meet the connector to be compressed.
- As soon as the pressing dies start to compress the connectors, the system
automatically switches from closing feed to working feed.
- Press until the pressure limiter can be heard or the pressing dies meet.
- Pressing the front operating button takes the pressure off the system and piston
travels back (fully or partially, to directly carry out a second compression action).

HAUPA GmbH & Co. KG, Königstraße 165-169, D-42853 Remscheid,
Tel.: [phone]. Fax: [phone], E-Mail: [e-mail]. Subject to technical changes and printing errors.
... convincing solutions
english
Mounting and unmounting the battery
Charger specifications
Model Nr.: 215527
Input: 100 – 240 V AC
Frequency: 50 / 60 Hz
Output V: 21 V
Output A: 1 A
Weight: 0,164 kg
Measurements: 92 mm (L) x 47 mm (B) x 45 mm (H)
Charger: Connecting battery to charger:

215523 (2 Ah) 215525 (4 Ah)
Please remove the battery after use and keep it removed when storing the
tool!
HAUPA is not liable for wrong or unintended use
2 Ah Battery Specifications
Model Nr.: 215523
Voltage: 18 V
Weight: 0,35 kg
Measurements: 114 mm (L) x 73,5 mm (B) x 67 mm (H)
est. Charging Time: approx. 30 Min
Capacity: 2 Ah
4 Ah Battery Specifications
Model Nr.: 215525
Voltage: 18 V
Weight: 0,58 kg
Measurements: 114 mm (L) x 73,5 mm (B) x 67 mm (H)
est. Charging Time: approx. 60 Min
Capacity: 4 Ah
LED charge indicator: (Pressing the button will light up LEDs)

Cleaning
• Careful cleaning of the tool, in particular, the moving parts contributes towards a longer
useful life. Remember that dust, sand, environmental influences, in particular a high salt
index, and dirt in general are extremely damaging to hydraulic tools.
• Particular care should be taken when cleaning the pump drive piston and the piston.
The tiniest of contaminations may scratch the walls of the cylinder and damage the
leak-proof seals. For the correct cleaning of the piston, we recommend extending the
piston and then cleaning it with a high-quality, non-corrosive solution.
Power switch
Check to see whether the switch on the machine automatically pops out again when you release
it.
WARNING NOTES!
A natural working position is required in order to operate the tool correctly, thus the handle must
point downwards.

Germany: HAUPA GmbH & Co. KG, Königstraße 165-169, D-42853 Remscheid.
Phone: [phone], Fax: [phone], [email protected] • Errors and technical changes reserved.
… convincing solutions
english
6. Fault diagnostics
Before you carry out any work on the tool, ensure that it is no longer connected to the power
supply.
CAUTION! If you have a problem that is not listed in the table below, contact your local tech-
nical customer support service for assistance.
6.1. WARNING NOTES!
Caution:
Do not attempt to force the head to turn when the hydraulic circuit is pressurised.
Guarantee:
2 year guarantee when used for the purpose it is intended when the annual maintenance
intervals are maintained by an authorised HAUPA service centre. We reserve the right to
rework the product.
Disposal:
Individual components must be disposed off separately.
The oil must be drained and disposed of at the designated points.
Caution:
Hydraulic oils represent a risk to the groundwater. Uncontrolled drainage or incorrect disposal
carries penalties. (Environmental Liability Law)
The remaining components of the aggregate must be disposed in accordance with the rele-
vant environmental standards.
The disposal should be carried out by authorised specialist companies. The free return to the
manufacturer cannot be guaranteed.
Always use original replacement parts. Other parts may seriously damage the tool and will
void the guarantee.
If the tool still does not work correctly, send it to the nearest repair service for specialist main-
tenance and fine tuning, or send an email to: [email protected]
WITH EVERY REPLACEMENT PART ORDER, INCLUDE THE FOLLOWING INFORMATION:
1) Article number.
2) Article description.
3) Reference to the operating instructions and/or date.
4) Tool type.
5) Serial number of the tool.
The guarantee is voided if you use parts that are not original replacement parts from HAUPA.

HAUPA GmbH & Co.KG, Königstr. 165-169, 42853 Remscheid, Germany
EC declaration of conformity
HAUPA factory certificate
Remscheid, 23.03.2016
Product:
Product range:
Art. no.:
Note: A correct connection according VDE 0220 Part 2 is only
guaranteed if the user work with Haupa cable lugs and also
adequate HAUPA pressing tools.
The tools are not isolated and it is forbidden to work under
tension.
HAUPA GmbH & Co.KG, Königstr. 169, 42853 Remscheid, Germany
Phone [phone] – 0, Fax [phone] – 840
Herewith we declare that the above mentioned tools are manufactured according the
following guidelines:
CE guidelines 98/37/EEC, 89/336/EEC
Jens-Ole Paas Jochen Husli
Qualitätsmanagement Produktmanagement
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Battery hydraulic crimping tool
Around the cable
215770; 215770/M; 215881; 215881/M; 216800; 216800-1
216801; 216801/M; 216601; 216622; 216503; 216663;
216663/M; 216667; 216667/M; 216669; 216669/M
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