Test Leads and Kits for the Automotive Market

Blog3_16In 1980 E-Z-Hook entered the automotive sector with our XJL insulation macro-hook connected to a lead with a standard alligator connector on the other side. This product 619XJL was offered in a black and red set of 18″, 36″ , and 60″ standard lead lengths. Today, 36 years later, this product can still be found in most automotive jobber trucks (think Matco, Snap-On, MacTool, etc). We have sold thousands of this product, which single handedly helped us enter the automotive after market for repair and testing.

Today the 619XJL remains a staple, and one of our most popular automotive leads. Variations of this test lead set include a straight banana plug connector or a shrouded right angle connector. All of these products work with most standard Digital Multi-Meters. For environments that require a higher heat resistance and more durability than our standard PVC wire provides, we do offer all test leads with silicone wire if requested.

In the early 90’s we introduced our XEL piercing hook into the automotive market. This narrower hook has an angled front to navigate through wire bundles, as well as a v-shaped design for grabbing and centering the wire or cable prior to piercing. It was introduced as an alternative lead set combination to the XJL options. In addition we designed it to be available without a factory installed lead. This XEL version offers a shrouded banana socket on either handle side, allowing easy flexibility to use with any standard banana plug lead. Much like our XJL versions, the XEL has become a popular staple in most auto repair and test mechanics tool boxes.

So, what next? As we spoke to distributors and automotive jobbers we realized that the automotive repair and test aftermarket really lacked in the “accessory” area. For most equipment companies the test leads and components were an after thought – and often not well designed or manufactured products. Automotive technicians would purchase fabulous multi-meters but the test cables supplied with these were often junk, couldn’t carry a proper signal, and needed replacement within a year. At E-Z-Hook these test leads, test cables, and connectors are our specialty. That is what we focus our manufacturing quality on so we could easily compete with great replacement products and test kits.

That is exactly what we have continued to do in these past 10+ years. Today in addition to our standard XJL and XEL test lead sets we offer various banana plug lead sets and individual leads specifically designed for automotive use. One of my personal favorites is our 9183-144BLK banana plug jumper test lead. Why do I like it – because while learning about our products for this industry I asked why in the world would we make something so long? 144 inches? 12 Feet? I was reminded that this length (the approximate length of a car) would allow a technician to be on one side and connect to something on the other. Made sense to me, and obviously to a lot of automotive test and repair technicians. Due to it’s popularity in the field we now bundle this test jumper in with many of our automotive kits. It can be purchased individually or is part of our popular 3519 and 3520 test lead sets. In addition to leads we offer various kits including our insulation piercing hooks as well as alligator clips, back probe needles and other connectors. All kits include various lead options and are offered with either our XJL or XEL piercing macro-hooks or the 8064 needle back probes which we just introduces to the market in late 2015.

Testing was never so easy. Over 35 years of PROVEN EXPERIENCE IN THE FIELD.

FIELD TESTING SOLUTIONS FOR POWER, UPS AND COOLING SYSTEMS

60140-Detail63340-RBE-Z-Hook is often best known for manufacturing “little things”  for test and electronic applications. These products are often used in a lab environment or designed to be connected or integrated as part of another manufactures test device or system. What many companies don’t know is that E-Z-Hook designs and manufacturers many products and kits for companies field employees and test engineers.

E-Z-Hook services a lot of industrial companies. We have created solutions for field employees that have taken us in different product directions then our “standard” lines. Our long-handled probe line is an industrial test solution used by field technicians predominately servicing AC POWER, UPS or COOLING SYSTEMS. Often these systems being tested are behind gated infrastructure, or it’s simply not safe for the technicians to be to close, let alone touch something directly. The long-handled probe has a hard straight tube which extends to 30″ for extra reach. This length (or distance) is important when testing, but a little long to carry around in your standard toolkit. Not a problem. The long probe was designed in two pieces, which can be easily and quickly screwed together on site. If purchased as a set they even come with a simple soft zipper nylon carry bag for immediate storage.

Long-handled probes are available with three standard wire length leads 36″, 48″, or 60″(measured from back of hard tubing to connector). While our most popular connectors are shrouded and standard banana plugs, these probe test leads can be customized with virtually any connector type. Interchangeable probe tips are also available pending the application need.

So next time you wonder how someone can test something behind a cage, or that says “warning- do not touch”- now you know. Just a reminder, these are for commercial use by trained field technicians.

 

E-Z-Flex connector kits service industries from aerospace to telecommunication

flexible test connectors, pins and sockets

The E-Z-Flex connector kits are available in two standard configurations.  Each kit contains sixteen connectors, both offering 4 unique sized pins and sockets in flexible insulated shields.

E-Z-Hook’s original flexible connector kit p/n 9099-0316 was designed for both the automotive and aerospace fields. Since it’s inception it has found popularity across multiple industries where electronic connections are required. This kit offers all connectors with a standard banana socket on one side, and eight varying sizes of gold plated pins and socket connectors on the other end. The pin and socket dimensions included in the kit are .030″ (.762mm), .040″ (1.016mm), .062″ (1.575mm), and .094″ (2.388). The flexible insulation is a molded plastic, provided in both red and black.

A few years ago E-Z-Hook was approached by a large US based generator company servicing the telecommunication, industrial, and commercial industries. They liked the versatility of the e-z-flex components, however they required a .080″ pin socket instead of a banana socket in our E-Z-Flex connector line. We created some customized  pin and socket dimensions specifically for their use.  This customer driven project made us recognize a simple need that many of our customers across industries required. With those requirements in mind E-Z-Hook created our 9099-0491 kit product line. This E-Z-Flex kit 9099-0491 was introduced in late 2015 and provides all E-Z-Flex connectors with .080″ pin sockets on the one side. When your connection component has a pin plug this versatile kit provides the solution.

All parts in both kits are also available individually for purchase.

flexible test connectors, pins and sockets

DEFENSE AND SECURITY APPLICATIONS

These handy little devices represent the XB product line created for the defense and security industries. Originally a “modification” to our 82-2 harness board product, these wire piercing devices are fully insulated on the exterior and offer a screw down clamp to ensure a secure and solid connection upon engagement with the wire. Once the XB is hooked on you can rest assured that it isn’t coming off until you decide to physically unclamp the device. The V-grove above the nailbed allows for various sized wire dimensions and ensures they can easily be directed over the wire bed for optimal connection. We understand there is often no room for technician error in the field- and this product was made with that requirement in mind.

The XB parts are available in red, yellow and black with factory installed leads. The most preferred lead is an 18 gauge PVC wire to a shrouded banana plug, but contact us for various connector options. This product is also available as a lead set or kit for specific industry requirements.

Power Company Test Leads

A large multi-state Mid-West power company approached E-Z-Hook to see if we could manufacture custom leads using the copper blade version of our macro-hook test connectors, model XH and XHL. The leads would ultimately be used by plant technicians testing power and required a secure right angle bend on the hooks.

Included in the requirement was the ability to close the power circuit after checking that the hook connection was properly connected. We designed in a “key” concept they requested. It was built into the jumper, allowing the user to close the circuit after the connection was verified as good. Additionally we designed jumpers with a similar fused “key” for further security which was required in some test environments. In the end, E-Z-Hook created four variations of leads, some containing a 3 AMP, 250 Volt fuse.

THINKING OUTSIDE THE BOX

IMG_2342IMG_2338E-Z-Hook has a long history of working with clients who need assistance developing a custom product to fulfill their needs. From the outside the solutions was simple – a box. It was the inside components, which included fuses and switches, that made the little box more complicated.

Working closely with the client E-Z-Hook developed 3 separate prototypes that could work with the clients test jumper applications. The final solution addressed the clients’ needs for a Test Jumper Junction Box. The finished product used both standard and custom components. The design included a toggle switch or momentary switch that allowed fuse capabilities to be switched on or off with the various test applications.
In the end, the solution was “in the box”, a small plastic box. The device allowed the customer to supply their technicians with a simply solution which allowed them to easily amplify their testing capabilities.  A single custom solution provided a complete kit.