Textron Klauke AHP 850-LC User manual

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The Power of Partnership
Gustav Klauke GmbH • Auf dem Knapp 46 • D-42855 Remscheid
Telefon ++49 [phone] • Telefax ++49 [phone] • www.klauke.com
HE.15323_C © 06/2014 R&D-2
GB Instruction Manual
AHP 850-LC
Battery-hydraulic Pump
Nominal voltage: 18V DC
Operating pressure: 850 bar (max.)
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Serialnummer
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HE.14176
AHP 850-LC
Instruction Manual Battery-hydraulic Pump
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Battery-hydraulic Pump
Nominal voltage: 18V DC
Operating pressure: 850 bar (max.)
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AHP 850-LC
Battery-hydraulic Pump
Nominal voltage: 18V DC
Operating pressure: 850 bar (max.)
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Instruction Manual Battery-hydraulic Pump
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4304711 batch# e.g. 304711
GN datecode e.g. „-GN“ for year 2013, month Jan.
142 consecutive# e.g. „142“ = tool # 142
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datecode
Year Code Month Code Month Code
2013 G Jan. N July V
2014 H Feb. P Aug. W
2015 J Mar. Q Sept. X
2016 K Apr. R Oct. Y
2017 L May S Nov. Z
2018 M June T Dec. 1

HE.15323_C © 06/2014
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Instruction Manual Battery-hydraulic Pump
III
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(BL1840) 36 min.
RAL40
CLICK
10 - 40°C
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pic. 10 Li-ion
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HE.15323_C © 06/2014
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AHP 850-LC
Instruction Manual Battery-hydraulic Pump
IV
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MT= 10 Nm max.
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HE.15323_C © 06/2014
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Instruction Manual Battery-hydraulic Pump
V
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AHP 850-LC
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Nominal voltage: 18VDC
Operating pressure: 850 bar (max.)
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HE.15323_C © 06/2014
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Instruction Manual Battery-hydraulic Pump
VI
Scope of delivery
Please check whether you received all parts
mentioned in the scope of supply:
Pos. Qty. Description Art.#
1 1 Battery hydraulic pump AHP 850-LC
2 2 Battery 18 V DC / 4 Ah / Li-Ion RAL40
3 1 Quick-charger LGL1
5 1 Shoulder strap TG3
6 1 Bag for accessories TT2
7 1 Instrucion manual HE.15323
8 1 Hand switch HTA4
3
6
7
1
2
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Battery-hydraulic Pump
Nominal voltage: 18V DC
Operating pressure: 850 bar (max.)
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HE.15323_C © 06/2014
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Instruction Manual Battery-hydraulic Pump
VII
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Accessories
The following accessories can be ordered:
Pos. Description Art.#
1 Mains adapter 18 V for 230 V voltage NG2230
2 Foot switch FTA4
4 USB-adapter PGA1
5 Digital meter for force and pressure measurement TC1U
6 Pressure sensor and connecting cable TP1000T
8 Adapter for CEJN-Male and Parker 3050-2 1/4“ Coupeling CMGSK
8
Tab. 2
When Why
20 sec after working cycle
2 x
after inserting
the battery Self check
20 sec/2Hz
after working cycle
20 sec/5Hz while exceeding
the temp. limit Unit too hot
20 sec
20 sec/2Hz
after working cycle
+
1

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Index
1. Introduction
2. Description of the electro-hydraulic pumping unit
2.1 Description of components
2.2 Brief description of the important features of the unit
2.3 Description of the tool indication
2.4 Description of crimping cycles
2.8 Description of reading procedure
3. Remarks in respect of the determined use
3.1 Operation of the unit
3.2 Explanation of the application range
3.3 Oil changing and maintenance cycles
3.4 Reference, as to which (spare-) parts can be exchanged by the customer
4. Troubleshooting
5. Technical data
Symbols
Safety Warnings
Please do not disregard to avoid injuries and environmental damage
Application Warnings
Please do not disregard to avoid damaging the tool.
1. Introduction
Before starting to use the tool please read the instruction manual carefully.
Use this tool exclusively for its determined use and follow all applicable safety instructions.
Mounting and assembly of connecting material with the help of this tool must only be performed by specially trained
personnel. The minimum age is 16 years.
This instruction manual has to be carried along during the entire life span of that tool.
The operator has • to guarantee the availability of the instruction manual for the user and
• to make sure, that the user has read and understood the instruction manual.

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2. Description of the electro-hydraulic pumping unit
2.1 Description of the components
The electro-hydraulic pumping unit consists of the following components:
Table 3
Pos. Description Function
1 Battery (RAL40/BL1840) rechargeable 4Ah Li-Ion battery (RAL40/BL1840)
Optional: mains adapter NG2230
2battery lock Slide to unlock the battery
3 Emergency stop button To reset the crimping tools into the starting position in case of an error.
4 Compartment ~ e.g. for remote control and/or carrying belt
5 Male plug Male plug to connect to a female plug on the hose
6 Socket for remote control, safety foot switch, two hand control and other controls
7 Oil plug Oil plug with inspection glass for the hydraulic oil
8 Program selection switch Turning knob for the selection of special programs for crimping, cutting, pun-
ching as well as a position to read out data.
9 OLED Display High tech organic display to indicate tool and crimping data
10 LED (red) Indicator for Battery charge, Service Intervals and faults
11 Forward and return keys To start/stop the working cycle
2.2 Brief description of the important features of the unit
The unit is equipped with a special brake which stops the forward motion of the piston/dies when the trigger is re-
leased.
Through an optional USB adapter a report can be generated at the end of a working session at a PC documenting
the proper function of the unit.
The unit is equipped with a double piston pump which is characterised by a rapid approach of the dies towards the
connector and a slow crimping motion.
All tool functions can be controlled by one rocker trigger. This results in an easy handling.

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The tool is equipped with a microprocessor which indicates service intervals and low battery charges and performs
internal checks.
Li-Ion batteries do neither have a memory effect nor self discharge. Even after long periods of non operation the tool
is always ready to operate. In addition we see a lower power weight ratio with 50% more capacity and shorter char-
ging cycles compared to NiMH batteries.
The oil used in our tool is particularly environmentally friendly and and has been rewarded „The Blue Angel“. The oil
is also suitable for low temperatures and has excellent lubrication characteristics.
The pump can be operated and transported in all positions without any oil leakages.
2.3 Description of the tool indication
This tool is equipped with a special circuit board incorporating several important features to inform the user about the
current status of the unit. Please see Table 2 for more details.
Prior to operating the unit the charging level of the battery should have been tested. A low charging level can be
detected by the LCD display.
2.4 Description of crimping cycles
During a crimping cycle the dies approach and finally contact each other. The connector mounted on a cable must
be located in the stationary half of the die whereas the moving die is approaching the compression point. The crimp
is complete when the dies contact each other and when the max. operating pressure is reached. For additional inst-
ructions please reference the assembly instructions in the Klauke catalogue.
A manual retraction stop with Teach-in allows the user to programm the stop position during the retraction of the pis-
ton so that the piston stops at the very position where the previous crimping/cutting cycle had been stopped.
3. Remarks in respect of the determined use
The pump can be transported and operated in any position.
Attention
In combination with a 2 m high-pressure hose it is not possible to work in a cable trench. For this application
at least a 3 m high-pressure hose is needed.
3.1 Operation of the unit
1. The female coupling of the hydraulic hose must be connected to the male coupling of the pump.
2. Select the right working unit for the intended application.
3. The selected working unit will be connected via the hydraulic hose with the pump
1

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Attention
Do not operate the pump without a working unit.
Attention
Before starting to operate the pump the oil level must be checked and possibly adjusted.
4. Besides the built-in trigger the following accessories can be connected:
• Remote control HTA4
• Safety foot switch incl. 4m cable FTA4
The pump recognises the various accessories through a special coding; the forward key will be deactivated accor-
dingly.
5. The battery and possibly the spare battery will be plugged into the sockets.
6. The pump is now ready to operate. The LCD display is activated.
7. Select the program for the intended application by turning the selection knob or the data function.
8. The working cycle is initiated by activating the advance function of the ‚forward and return keys‘
Attention
The crimping cycle can be stopped at any time by releasing or stepping down the actuator of the safety foot
switch, resp. releasing the two hand safety switch .
Once the three step safety foot switch has been stepped down, it can only be reactivated by pushing the reset button
of the foot switch. This reset button is located on the top of the foot switch.
Attention
After having terminated the working cycle and prior to changing the dies remove battery to avoid un-
intended use. Avoid unintended starts. Make sure the switch is in the off position before plugging in.
For transport turn the program selection switch to position 7 to avoid unintended starts.
3.2 Explanation of the application range
The battery hydraulic pump can be operated with all of the crimping heads in our catalogue.
Attention
Do not crimp on live cables or conductors.
Before starting to work make sure there are no live lines in the working area.

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The tool is not designed for continued operations.After a sequence of approximately 100 completed cycles 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 explosi-
ve liquids and materials
Attention
Electric-hydraulic tools should not be operated in pouring rain or under water.
The tool can be operated in a temperature range of -12°C bis +40°C inside as well as outside.
3.3 Oil changing and maintenance cycles
For every day service the tool has to be cleaned and dried after each use. The battery cartridge and the charging unit
have to be protected against humidity and dust.
The pump has an oil plug with inspection glass which can be used to determine the proper oil level. If the oil level
should be too low the reservoir must be refilled.
The following hydraulic oils are suitable for a temperature range -12°C to +40°C:
Hydraulic oils based on Ester: Rivolta S.B.H. 11, Shell Naturell HF-E 15
Mineral oils: Shell Tellus T 15, AVIA HVI 15, Mobil DTE 11, NUTO H 15, Rando HD - Z15, Agip OSO 15, BP Energol
HLP 15.
Other equivalent hydraulic oils can also be used.
The hydraulic hose and the armature must be checked for damage and leakage.
Attention
Maintain power tools thoroughly. Check for functionality or jamming of moving parts, breakage of parts and
any other condition that may affect the power tools operation.

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The battery-hydraulic pump is equipped with a controller enabling the user to see when the next service is due by
flashing for 20 sec. at the end of a working cycle. When the next service is due after 10.000 cycles the unit must
be returned to an authorised service center (ASC). Failure to observe this request results in loosing the Warranty.
Preventive maintenance serves your safety. Within the determined use of the tool only the batteries are permitted to
be changed by the customers.
Attention
Do not damage the seals of the tool
Attention
Have the power tool repaired by a qualified expert or by a Klauke ASC before use.
It is advisable to have the pump serviced by a specialist during regular intervals to safeguard a technically proper
state before use.
Table 2 - Service schedule
What? When? Who?
Cleaning after each use Service personnel
Check oil level weekly Service personnel
Check high pressure hose weekly Specialist
Proper state quarterly Electric specialist
Change hydraulic oil annually Manufacturer/Specialist
The hydraulic oil has to be completely changed annually or after 10.000 working cycles.
We recommend to have the service done in specialised companies where the save disposal of the oil is guaranteed
for environmental protection.
Attention
Please use only clean, proper hydraulic oil. (Rivolta S.B.H. 11 and other hydraulic oils of similar quality)
Attention
Hydraulic oils can cause cutaneous eruption (eczema) or other health hazards. Avoid longer skin contact.
Wash your hands carefully after each contact.

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Attention
Spilled hydraulic oil has to be absorbed immediately.
3.4 Reference as to which spare parts can be exchanged by the customers
Within the determined use of the tool the customers may only change the oil.
Attention
Do not damage the seals of the pump.
Do not attempt to repair the tool yourself, and do not remove any parts such as screws and other components.
4. Troubleshooting
a.)Constant flashing/indicating of the red LED.
see tab. 2. If the failure can not be resolved through the action recommended in tab. 2 return the unit to the
nearest service center (ASC).
b.)The tool or the crimping head loses oil.
Return the unit or the accessories to the manufacturer. Do not open it and damage the seal of the tool.
5. Technical Data
Protective system: IP 43 Driving motor: direct-current permanent field
max. operation pressure: 850 bar Weight of the unit: approx. 4,9 kg
Hydraulic oil: Rivolta S.B.H. 11 Battery voltage: 18 V
Reservoir capacity: approx. 760 ml Battery capacity: 4 Ah (RAL40/BL1840)
Useable oil capacity: approx. 740 ml Charging time: 36 min. (RAL40/BL1840)
Environmental temperature: -12°C bis +40°C Sound level: < 70 dB (A) in 1m distance
Control voltage: 18 V DC Vibrations: < 2,5 m/s²
Remark
Additional instruction manuals are available free of charge. The part # is HE.15323.
The Instruction Manual can also be downloaded from our Homepage www.klauke.textron.com.

HE.15323_C © 06/2014
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