GAZELLE G9622 Hydraulic Crimping Tool User Manual

GAZELLE G9622 Hydraulic Crimping Tool User Manual

Introduction

• Use this tool exclusively for its determined use.
• 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 must be carried along during the entire life span of that tool.
• The operator has
  • to guaranty the availability of the instruction manual for the user and
  • to make sure, that the user has read and understood the instruction manual.

Labels

On the labels fixed on the unit you’ll find the type specification name of the manufacturer and/or the company logo. On the cylinder you find the serial number.

Warranty

If correct operation is guaranteed and regular service is provided our warranty is 1 year from the time of delivery.

Description of the hydraulic crimping unit

The hand-hydraulic crimping unit type HCT-12042 is a hand-held tool and consists of the following components:

in to starting position
5| Guiding handle| To guide and position the tool
6| Turn screw| To activate the transportation lock

Remarks in respect of the determined use

Operation

First you have to select the right dies for the intended application.

Attention:
Don’t use the tool without dies

1. Afterwards the dies will be inserted laterally into the crimping head until the die lock engages and locks the die securely. Then the connecting material must be positioned in the crimping. In order to start the crimping procedure, the turn screw must be turned 180°while the pump lever is pushed towards the handle.
2. A crimping process is initiated by activating the pump lever. It is defined by the closing motion of the dies. The connecting material is positioned in the stationary half of the crimping dies and the moving part is approaching the compression point.
3. The tool is equipped with a double piston pump which is characterized by a fast approach of the die towards the connecting material and a slow working speed with  forces to crimp the connector. In the low-pressure mode, the fast approach is realized while opening the pump lever and the slow by closing it. In the high-pressure mode,the compression is realized by closing the pump lever only.
4. A crimping cycle is terminated when the dies contact each other and when the maximum crimping force is reached. This is indicated by a significant decrease of the handle force.
5. After the crimping is completed, if the rated pressure value is not reached, the return lever can be used to manually return the piston to the starting position to achieve pressure relief and return oil; if the rated pressure value has been reached, the tool will automatically release the pressure and the piston will automatically retract. Afterwards a new crimping cycle can be initiated or the crimping process can be terminated and the connecting material removed out of the crimping head.
6. Before storing the tool the turn screw has to be turned 180°and the handles must be closed until the lock is activated.

Explanation of the application range

Our hydraulic crimping tool has a large number of various dies available to crimping primarily copper and aluminum but other connecting materials.

Table 2

5mm
6-240| TCL and C. DIN46235/DIN46267| CU, ,,QS“ DIN46235| code#| Chrome plated(yellow)| 5mm
10-240| Aluminum CL and C.| AL, ,,QS“| code #| Blue zinc| 7mm
25-185| aluminum C.High-strength aluminum wire| AL, ,,QS“| code #| Blue zinc| 7mm
25/4-120-20| Full tension C.| AL, ,,QS“| code #| Blue zinc| 7mm
| | ST, ,,QS“| code #| black| 5mm
10-240sm35-300se| Pre-rounding dies| RU；QS，sm；QS，sm；| –| Chromeplated (yellow)| –
10-70| Terminals DIN46234/46230| CU, ,,QS“ DIN46234| ,,QS“| Chrome plated(yellow)| –
10-70| Insulated terminals| ISQ, QS| ,,QS“| Chromeplated| –
10-70| Tub.CL.for fine-str.conductors| F, QS| ,,QS“| Chromeplated| –
4-50| C clamps| C, QS| –| Chromeplated| 5mm
10-150| Pre-insulated tub.CLTand connectors| IS, QS| ,,QS“| Chromeplated| –
2×50-2×70| Double CL| DP, QS| ,,QS“| Chromeplated| 5mm
10-50| Ni-Cl and connectors| NI, QS| –| Blue zinc| 5mm
10-70| Oval connectors| CU or ALQS| code #| Chromeplated| 5mm
10-185| WF DIN 46228| AE, QS| –| Chromeplated| –
2×4-2×16| Double WF| AE,2×QS| –| Chromeplated| –

Attention
Do only crimp copper and AL conducting material or special connecting material mentioned in table 2.
Do not crimp on live cable or conductors.

Mounting instructions
If other application that exceeds those mentioned in table 2 must be performed with this tool it is necessary to contact the manufacturer.

Despite the same numbers the compression width for copper and aluminum cable lugs and connectors is different. Besides the marking of the dies the plating is different too.

**** Even if the code number is identical only those dies should be used which are suitable for the material.

Service and maintenance instruction
The hydraulic crimping unit has to be cleaned and dried after use. The unit is basically maintenance-free, only the bolt joints have to be oiled regularly.

Storage and transport of the crimping tool
In order to protect the tool against damages it has to be cleaned carefully after every use and be put into the transportation case which has to be close safely.

Reference as to which spare parts can be exchanged by the customer
Within the determined use of the tool only the dies are permitted to be changed by customer.

Troubleshooting

1. The dies came to a standstill during the crimping process respectively the crimping tool doesn’t reach the final operation pressure.
   =>Actuate the pump lever and simultaneously push the retract lever.

2. The tool loss oil
   => Return the tool to the manufacturer. Do not open the tool and damage the seal of the tool.

Putting out of operation/wasted disposal

The disposal of the various components of the tool has to be treated separately.
Doing that the first step is to dispose of the oil at special delivery points.

Attention
Hydraulic oils represent a danger for the ground-water. Uncontrolled draining of or improper disposal is under penalty (environmental liability law)

Technical Data

Crimping head can be turned 360°in a pressure free state.

Weight of the crimping tool： 6.1KG
Crimping force： 120KN
Stroke： 42mm
Rated pressure: 700bar
Crimping capacity: Max 400mm²
Standard dies: Cu50-400mm²
Dimensions: 56177cm

We shall in no event be liable for death, injuries to persons or property from the improper use and lack of maintenance of our product. Any doubt of safety operation and precaution, please contact with our distributor.

Please properly dispose of all packing materials and removed parts.

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