Makita ESC125 Owner's manual

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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
Page : 1/10
Créé / MAJ le : 28/01/2020
By : Karine LAFON
Visa :
Up dated on : 28/01/2020
By : Vivien ROQUE
Visa :
Approved on : 28/01/2020
By: Aurelien BESSE
Visa :
Archivage : /
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ELECTROHYDRAULIC BATTERY CRIMPING TOOL
ESC125

19231 Pompadour
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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
Page : 2/10
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1SPECIFICATIONS :
Technical features :
Output force : 120kN
Piston stroke : 25mm
Engine power : 320W
Weight : 6.6kg (including battery)
Head C weight : 260gr
Dimensions : 385 x 315 x 72 mm
Voltage : 18VDC
Battery type : BL18xx
Housing molded with PA6-30GF
180° rotation head
Programmable return (auto or manual)
USB connection to CTDiag software
1 Battery charge Led
1 Service Led
Crimping specifications :
Matrice C12
Section maxi cuivre : 400 mm²
Section maxi aluminium : 300 mm²
Temps de cycle en sertissage : 5 à 8 sec
Autonomie en sertissage : 100 à 220 cycles avec batterie 4.0Ah
Electronic configuration :
Female micro-USB connector
Programmable return (auto or manual)
Access to number of cycles
Access to service history
CTDIAG software compatibility
BL1840 battery:
Voltage : 18VDC
Capacity : 4.0Ah
Technology : Li-ion
Dimensions : 116 x 72 x62 mm
Weight : 0.64kg
CLM1890HC charger:
Voltage between 7.2 to 18.0V
Technology : Ni-Mh / Li-Ion
Charge current : 9.0Ah
Power supply voltage : 220VAC
Socket : EU
Dimensions : 190 x 155 x 85 mm
Weight : 0.85kg

19231 Pompadour
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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
Page : 3/10
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Safety informations :
Hydraulic oil : Total Equivis XV32
Crimping head limit life time : 15000 cycles
Tool service life : 40000 cycles

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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
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2–DESCRIPTION OF THE TOOL
1
2
3
4
9
10
11
12
5
6
7
8

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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
Page : 5/10
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1. Die Release Pin.
2. « C » Head.
3. ON/OFF Trigger.
4. Return Trigger.
5. Oil tank cover.
6. Emergency return system cap.
7. 3-Color Service Led.
8. 3-Color battery power load Led.
9. Nylon suspension straps.
10. PA6-30GF molded housing.
11. USB connector protection cap for CTDiag software connection.
12. Battery locking system.
3. SAFETY RULES.
•Never install or replace the two half-dies with a battery inserted in the machine.
•Never operate the tool without die and connector in place.
•Avoid simulating crimping operation with dies whose closure contact surface area is reduced
because of the size of the groove.
•Never insert a damaged or cracked battery into the tool.
•Keep the head clean and free of particles.
•Keep an adequate and balance position at all times.
•Never point the tool head in direction of people.
•Never use this tool near inflammable or explosive materials or in an inflammable atmosphere.
•Never let the tool fall.
•Never expose the tool to oil or solvent projection. Even though it is designed for outside use, protect
it as much as possible from water projection.
•This tool is not insulated for use on or near live line cables. Use this tool near live line
conductors may lead to electrical shock, causing severe injury or death. Do not use this tool
near live line conductors without adequate protection and control.
4. OPERATION INSTRUCTIONS
4.1. Inserting of C12… dies
Move the piston forward (about 15 mm), in order to be able to press the die release pin.
Remove the battery to prevent any unexpected activation.
Choose the right set of dies to crimp the connector. Check that the set of dies is clean.
Press the return trigger (4) and locate one half die in the top of the head, center it and release the pin.
A click can be heard when the retainer pin in the top of the die way engages in the die slot.
Locate the second half die in the piston as indicated before.
4.2. Fitting and changing the battery.
Fit the BL 1840 battery after having checked the cleanliness of the electric contacts.
To insert the battery, align it with the groove in the tool housing, then slide it into place. Always push
it fully until a slight click is heard.
Never force when inserting the battery. If it does not fit easily it means you are not inserting it
properly.
To remove the battery, slide the locking button (12) downwards, then pull the battery out by sliding
it.

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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
Page : 6/10
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The tool's battery charge indicator indicates the remaining charge:
•Green: remaining charge > 20%.
•Orange: remaining charge < 20%, plan a charge.
•Red: battery completely run down; the tool will no longer run in order to protect the battery
from deep discharging.
4.3. Starting the tool.
After an extended period of time without use, the tool switches to stand-by mode to maintain its
autonomy.
To activate the tool, press the On / Off trigger (3). The tool LEDs will turn on to indicate the battery
and tool status.
Caution: For reliability reasons, a timer prevents the tool from operating if the triggers are pressed
too frequently.
4.4. Tool heating..
The tool is filled with high viscosity oil TOTAL EQUIVIS XV 32 and has an operating temperature
of -20°C to +60°C. Nevertheless, if it has been stored for a long period at a temperature below -5°C,
it is recommended to warm it in a temperature place. At least 3 empty crimps must be carried out
before starting crimping, it will work better.
4.5 Operation.
•When the connector to crimp is installed in the dies, work can begin. Hold the handle with one hand
and keep the other at about 10 cm from the head.
Never place hands near the moving parts.
•Press the On/Off trigger (3), the tool will build pressure until it releases automatically and then
stops indicating that the crimping is complete.
•In the case of an automatic return, the piston will retract after the motor has stopped. Its return can
be stopped any time by pressing one of the triggers.
•With the manual return, press the return trigger (4) to actuate the piston return.
•A complete return is required to remove the crimped connector. When several crimping operations
are needed on the same connector, it is recommended to make limited retractions which are sufficient
to allow the movement of the tool on the connector. During an indenting operation, the indent must
be fully retracted to enable tool movement.
•Once the dies are in contact with the connector the return can no longer be actuated. The crimping
must be completed and the tool triggered to be able to activate the return.
•The battery LED may change color during the crimping. This is normal and should be ignored.
4.6. Noise level
Noise transmission values declared
In accordance with ISO 4871
A-weighted emission sound pressure level, LpA
(reference 20 µPa), in decibels
68
Uncertainty, KpA, in decibels
3
Reference standards: NF EN ISO 3744 et NF EN ISO 11201
Measurements based on the standard NF EN ISO 15744
4.7. Acceleration
Acceleration transmission values declared in accordance with EN 12096
Work cycle
Measured value of
acceleration, a
Uncertainty, K
"Hand-Arm" vibration
empty
< 2,5 m/s²
-
Values determined in accordance with the standard NF EN ISO 20643

19231 Pompadour
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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
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5. MAINTENANCE.
5.1. Daily maintenance
•A daily maintenance is required to ensure that the tool is kept in good working condition. Wipe it carefully
with a dry cloth to remove any dirt. Never use solvent for this operation. If the tool has been used in rainy
weather, wipe and dry it completely before storage.
•The head can be cleaned using a gentle solvent (petrol). To do this, hold the tool with its head
down and protect the plastic shell. Wipe and dry.
•The shell can be cleaned using a cloth soaked in soap and water. Never use solvent as some
solvents may attack the plastic material.
•Store the tool in its box in a temperate and dry place (see the battery instructions).
5.2. Indicateurs d’états.
This tool is equipped with two 3-color LEDs to inform the user of its service and battery status.
•Service LED :
- Green fixed light : Tool in working order.
- Green blinking light : Tool in working order, Maintenance to be planned : Schedule to
return the tool to the factory or to an approved workshop.
- Green/Red blinking light : Tool in working order, Maintenance is required : Return the
tool to the factory or an approved workshop.
- Orange fixed light : Power at the limit of tolerance : Schedule to return the tool to the
factory or to an approved workshop.
- Orange blinking light : SD Card or GPS fault : Return the tool to the factory or an
approved workshop.
- Red fixed light : Power out of the tolerance / Cycle time too long : Return the tool to the
factory or an approved workshop.
- Red blinking light : Temperature out of range : If the temperature is too high, leave the
tool to cool for 15 minutes. If the temperature is too low, place it in a temperate room.
•Battery LED :
- Green light : Battery charge upper than 20%.
- Orange light : Battery charge between 0 and 20%: Plan to charge it.
- Red light : Battery charge nearing 0%: Chargethebattery. The tool will not restart in order
to avoid deteriorating the battery through deep discharge.
5.3. Replenishing of oil.
It is recommended to check the hydraulic fluid level every month, and to change it every year or two
years depending on use. The volume of hydraulic oil in the tool tank is about 100 cm3.
•Fully return the piston.
•Remove the battery.
•Remove the oil tank cover (5).
•Keep the tool vertical with the head facing down.
•Remove the cap by turning it and firmly holding the notched part of the tank. Wipe the magnet fixed
in the tank cap to remove any metal particles that may be attached to it.
•Refill with EQUIVIS XV 32 oil using a small squirt until it reaches a few millimeters from the edge
of the tank.
•Refit the cap expulsing any air from the top of the tank.
•To purge all the air, run the tool several times with dies, with the head pointing down, then refill the
tank if necessary.
•Carefully wipe any excess of oil and refit the cover (5).

19231 Pompadour
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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
Page : 8/10
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5.4. Output force checking and adjustment.
5.4.1. Checking.
•It is recommended to check every year or 10000 cycles the output force of the tool to insure the
quality of the crimping operation. To do this operation a dynamometer is required and refer to its
instructions for use.
•The output force must be measured within the recommended tolerance.
5.4.2.Adjustment.
This adjustment is only required when the output force is out of the recommended tolerances.
Normally, this adjustment is not required before 10,000 crimping operations.
As the adjustment requires specific tools and a partial opening of the tool, it should be carried out
by a Cegers-Tools approved workshop or by people who have been trained to the tool maintenance.
5.5. Emergency manual return procedure.
Remove the emergency return system cap (6).
Insert a round tool with a diameter between 4 and 6 mm.
Press to activate the return manually.
This will open a hydraulic valve to enable piston retraction.
5.6. Choice of return.
The return can be configured in automatic or manual mode with the CTDiag software.
Automatic return : The return is activated after the motor stops at the end of the cycle. The return can
be stopped at any time by pressing one of the two triggers.
Manual return : The tool stops at the end of the cycle. The return trigger (4) must be used to activate
the return.
Caution : The tool must be restarted to take the software configuration into account. Wait for the
LEDs to turn off, then activate the tool by pressing the On/Off trigger (3).
6. TROUBLESHOOTING.
6.1. Impossible to fit a die.
•The tool head is designed to receive C12… die sets designed by CEGERS TOOLS.
•If the die compliant with one of these standards has no traces of impacts and deformation at the
sliders, check the housing in the head, the piston and the adapters.
•If the die is not an original from Cegers-Tools, there is a risk of permanent damage to the sliders
and early deterioration to the head (See the WARRANTY section).
6.2. No reaction when powering on.
•Check that the battery is charged (Battery LED green or orange) and that the contacts are perfectly
clean.
•If these two checks are positive but the tool is still not working, it should be returned to the factory
or to an approved workshop (defective motor, electric or electronic component).

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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
Indice : A
Page : 9/10
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6.3. The piston do not move, stops in mid-movement, or has a jolting movement.
•Presence of air or lack of oil in the hydraulic circuit. Fill as explained in § 5.3. Make the tool work
several times with the head downwards and fill it again.
•If the problem still exists, some air is probably trapped in the high-pressure circuit and the tool has
to be sent back to the workshop. For this reason, a current maintenance and frequent control of the
oil level are essential.
6.4. The piston moves slowly.
The suction check valve is defective, the tool must be checked. The tool must be returned to the
factory or sent to an approved workshop.
6.5 The piston moves forward and backward but does not move advance.
The check valves are no longer operational. The tool must be returned to the factory or sent to an
approved workshop.
6.6 The piston stays jammed in the high position.
The tool is blocked under pressure. Press the On/Off trigger (3) to activate the relief valve. If the
piston remains jammed, activate the manual return as described in § 5.5.
6.7. Crimping is not complete.
6.7.1. The relief valve worked.
•Check the die is the recommended one for the connector to be crimped.
•Check the output force adjustment as described in § 5.4.
6.7.2. The high pressure relief valve do not work.
•Return the tool to workshop for repair and valve adjustment.
6.8. Hydraulic fluid leakage near the crimping head.
•The piston O-ring is worn. The tool must be returned to the factory or sent to an approved
workshop.
6.9. Hydraulic fluid leakage in the shell.
•The oil tank has a leakage or the high pressure piston gaskets is worn: the tool must be returned to
the factory or sent to an approved workshop.
7. WARRANTY.
This pump is manufactured and controlled with the greatest of care and is guaranteed for 24 months, from date
of purchase within the limits of the crimping head service life of 15000 cycles.
The guarantee implies free replacement of any defective part during normal use, but excludes any damage due
to misuse, shock and/or faulty maintenance. This guarantee will automatically be cancelled when the tool is
dismantled, or if any modification has been made or attempted.
The application of the guarantee does not imply liability to any damage, and, in no case, it will give rise to any
compensation.
The tool must be returned in its original packing to CEGERS TOOLS or to their official Dealer.

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TOOLING TECHNICAL INSTRUCTIONS
ELECTROHYDRAULIC BATTERY CRIMPING TOOL
Form. n° : 332
Indice : B
Doc n° : 332 3036
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Connecting Solutions
ZA Les Hauts de Chignac
19230 POMPADOUR
FRANCE
Tél. : [phone]
Fax : [phone]
Courriel : [e-mail]
Site internet : www.mecatraction.com