haupa AH-6 User manual

Q
ZERTIFIKAT
DIN EN ISO 9001
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INSTRUCTION MANUALHydraulic crimping tools
Electro hydraulic crimping tool
„AH-6“
Art. 215880

1. Technical data Art. 215880
Area of application: For the creation of an electrical connection by means of compression
Scope of delivery: 1 crimping tool, 1 charger, 2 batteries, 1 carry strap, in plastic case,
without dies.
Pressing force: 60 kN
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. 215880 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 Art. 215880
3. Operating instructions
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 exclusi-
vely for the purpose for which it is intended.
Only electro-technically trained persons over 16 years of age may process connecting materials
using the tool.
• Pressing force in kN: 60 kN
• Working pressure in bar: 700
• Head can be opened
• Opening / Hub: 17 mm
• Pressing width: slim
• Motorstop
• Crimping range cable lugs: Cu 10-240 / DIN Cu 10-240 / DIN Al 16-185
• Crimping range connectors: Cu 10-240 / DIN Cu 10-240 / DIN Al 16-185
• Pressing time, battery-operated in seconds: 6
• Battery charging time in minutes: 60
• Battery type: NiMH, 14,4 V, 3 Ah
• Dual-piston pump
• Length in mm: 335
• Weight in kg: 4,5
• Weight Set in kg: 8,5

Germany: HAUPA GmbH & Co. KG, Königstraße 165-169, D - 42853 Remscheid.
Phone: [phone], Fax: [phone], [email protected] • Errors and technical changes reserved.
english
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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.
• Insert the pressing dies in the tool head. 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.
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.
Die holder
Pushbutton
to advance
Pushbutton for
return movement

- 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).
4. Removing and inserting the battery
Hold the tool firmly and press the battery release button to remove the battery.
ATTENTION:
Never short-circuit the battery.
Inserting the battery
Insert the battery until it clicks into place. Make sure the poles are facing the right way.
Charging
Before using the tool, charge the battery as follows:
Connect the cable of the charger to a socket (AC). As soon as the
charger is connected to the power supply, the red LED will light up.
Inserting the battery into the charger
Insert the battery firmly, as shown in Figure 2 shown here,
until it touches the bottom of the charging compartment.
ATTENTION:
If the battery is inserted incorrectly (Figure 1),
it will not only not be charged, it may also damage the charger
(e.g. by bending the terminals/short-circuiting).
Charging
When you insert a battery into the charger, the battery will start charging
and the green control light will also light up.
When the battery is fully charged the green control light will flash.
If the yellow control light comes on, the battery is overheating. Remove the battery immediately
and disconnect the charger from the power supply.
Illustration 2
Illustration 1

Germany: HAUPA GmbH & Co. KG, Königstraße 165-169, D - 42853 Remscheid.
Phone: [phone], Fax: [phone], [email protected] • Errors and technical changes reserved.
english
… convincing solutions
5. Care and maintenance
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.

Filling level of the oil tank
Ensure that the oil level is always sufficient. Do not fill the tank with unsuitable oil or brake fluid. Oil
type: VESTA HLP-15 from VERKOL or an oil of a similar quality. Remove the tank lid and top up the
oil. The oil must be filtered first. If necessary, purchase the required oil from the HAUPA (Art.
216254).
Storage
To prevent damage to the tool as a result of bumps, dust etc. you should if possible store the tools
in the original packaging.
Oil level
The oil level in the tank should be checked at regular intervals, in particular, when it has been used
for a long time and topped up whenever necessary.
Oil filling
This process should only be carried out by an authorised technician.
Important: The hydraulic oil must be filtered, have an ISO viscosity class of 15 and a viscosity index
of 100 and correspond to the standards AFNOR NFE 48603-HM and ISO 6743/4 L-HM.
Turn off the cap and fill in
the oil on demand

Germany: HAUPA GmbH & Co. KG, Königstraße 165-169, D - 42853 Remscheid.
Phone: [phone], Fax: [phone], [email protected] • Errors and technical changes reserved.
english
… convincing solutions
6. Diagnosing faults
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
technical customer support service for assistance.
PROBLEM POSSIBLE CAUSE SOLUTION
The tool does not move, moves
slowly or jumpily forwards
Air in the system Hold the pressing head upright an press the
operating buttons for feed and the release valve
simultaneously for around 10 seconds
Oil level low Fill oil in accordance with the instructions above
Cylinder piston jammed Check the cylinder for damages.
Contact [e-mail]
Leaks on the installed pump Contact [e-mail]
The tool does not move, only
partially or moves slowly
Air in the system Bleed as described above
Return spring damaged or other
damage to the cylinder
Contact [e-mail]
Oil loss at piston O-rings damaged Contact [e-mail]
Crimp process is not completed or
does not return to the basic
position
Battery is not sufficiently charged,
therefore there is not sufficient
hydraulic energy to release
Insert the replacement battery. Ensure that the
replacement battery is always charged.
CAUTION: Pushing the operating button too firmly
may cause damage to the release valve.

Always use original spares. Any other part type could seriously damage the tool and void the guarantee.
If despite the above, the tool still does not work correctly, return it to the nearest Technical
Service for repair and fine tuning by specialised personnel or send an e-mail to:
[email protected]
WHEN ORDERING SPARES, ALWAYS PROVIDE THE FOLLOWING INFORMATION.
1. Item code number
2. Item description
3. Instruction manual reference and/or date
4. Tool type
5. Tool serial number
The guarantee will become void if spares other than the HAUPA original spares are used.
Spare parts list art. 215880
No. Description PU
1 PLASTIC BOX 1
2 PLASTIC BOX 1
3 UP PLASTIC CAP 1
4 BATTERY 14.4V 1
5 PUMP BODY 1
6 SCREW (CHEK VALVE) 1
7 SPRING 1
8 BALL CAP 1
9 BALL3/16" 3
10 BALL 4.0 MM 2
11 SCREW 2
12 SPRING 1
13 O RING (P-4) 1
14 BACK -UP RING (P-4) 1
15 SCREW 1
16 WASHER 1
17 VALVE BASE 1
18 VALVE BODY 1
19 VALVE ROD 1
20 VALVE BODY 1
21 SCREW 1
22 SPRING 1
23 WASHER 1
24 VALVE BODY 1
25 OIL FILTER 1
26 SNAP RING 1
27 RELEASE VALVE STEM 1
28 O RING (P-3) 1
29 O RING (P-8) 2
30 BACK UP RING 1
31 PIN 1
32 O RING (G30) 1
33 OIL RESERVOIR 1
No. Description PU
34 OIL RESERVOIR PLUG 1
35 ALUM - HEAD 1
36 RELEASE 1
37 SPRING 1
38 NUT 1
39 SCREW 7
40 WASHER 4
41 BEARING 1
42 WASHER 1
43 BEARING 1
44 ROTATION ROD 1
45 PISTON 1
46 BEARING 1
47 BEARING BASE 1
48 FIRST GEAR BASE 1
49 FIRST GEAR PART 7
50 RING GEAR 3
51 RUBBER WASHER 2
52 SECOND GEAR BASE 1
53 SECOND GEAR PART 4
54 THIRD GEAR BASE 1
55 THIRD GEAR PART 4
56 WASHER 1
57 GEAR BOX 1
58 SCREW 2
59 WASHER 1
60 SCREW 6
61 GEAR 1
62 MOTOR 1
63 LOCK RING 1
64 SPRING 1
65 MONITOR 1
66 PROTECT CAP 1
No. Description PU
67 SCREW 3
68 SCREW 3
69 SCREW 1
70 SCREW 2
71 SWITCH 1
72 PIN 1
73 SPRING 1
74 SPRING 2
75 PLASTIC FIXED PIECE 1
76 SCREW 4
77 RELAY 1
78 SWITCH 1
79 SPRING 2
80 INSULATE PLATE 1
81 LOCK PLATE 2
82 CONDUCTION PLATE 2
83 PIN 1
84 O RING 1
85 BACK UP RING 1
86 PISTON 1
87 SCREW 1
88 SPRING 1
89 CAP 1
90 SCREW 1
91 MOLD BASE 1
92 UP DIE HOLDER 1
93 SPRING 1
94 LOW DIE HOLDER 1
95 SPRING 1
96 PIN 2
97 SNAP RING 4