GAZELLE G9634 Battery Powered Hydeaulic Crimping Tool User Manual

GAZELLE G9634 Battery Powered Hydraulic Crimping Tool User Manual

Product Information

Product Description

The product is a hydraulic crimping tool designed for crimping various types of cables and terminals. It features a compact design and easy handling, making it suitable for both professional and DIY use.

Instruction of product

The product comes with a user manual that provides detailed instructions on how to operate and maintain the tool. It is important to read and understand the instructions before using the product. Thank you for purchasing and using battery hydraulic tools. The battery hydraulic tools are powered by high- performance lithium batteries, driven by a motor, a two-stage hydraulic system, automatic pressure relief, built-in smart computer chips, an OLED display for easy reading of information, and LED work lights to make work more convenient. The toolbox is made of environmentally friendly engineering PP plastic, integrally formed, resistant to pressure and drop. It is your professional tool for crimping wires and copper/aluminium terminals in electrical construction

Description of each part

The product consists of the following parts:

1. Button – Used for various functions and operations.
2. Crimping dies – Replaceable dies for different crimping needs.
3. Lighting lamp (LED) – Provides illumination during operation.
4. Warning light – Indicates any warning signals or errors.
5. Reset button – Manually resets the piston in case of selecting the wrong cable.
6. Trigger – Starts the motor and performs crimping.
7. Battery – Rechargeable Li-ion battery for power supply.
8. Sling – Used to carry or hang the tool for convenience.
9. OLED screen – Displays various data and settings.

Function description

The hydraulic unit incorporates an automatic retraction which returns the piston into its starting position when the maximum operating pressure is reached.

A manual retraction allows the user to return the piston into the starting position in case having selected the wrong cable.

Miniature two-stage hydraulic system-the piston will advance quickly during the low pressure crimping process, and the piston will advance slowly after the dies contacts the terminal

The head can be smoothly turned by 360°around the longitudinal axis in order to gain better access to tight corners and other difficult working areas.

One significant sound will be heard and a red display flashes if any error occurs.

The whole tool is controlled by one trigger. This results in an easy handling and a better grip compared to a two buttons operation.

Lithium batteries are recommended to be fully charged every 2 months. In addition, compared with nickel-hydrocarbon batteries, the storage capacity is 50% higher, the charging is fast and the time is short.

A temperature sensor makes the tool stop working automatically when the temperature over 60℃ under long time working, the fault signal sounds, it means the tool can’t continue work until the temperature reduce to the normal.

The product has the following functions:

• Lock or remove the crimping dies for easy replacement.
• Illumination feature with LED lighting lamp.
• Show warning signals through the warning light.
• Manually reset the piston in case of select the wrong cable.
• Start the motor and perform crimping using the trigger.
• Rechargeable Li-ion battery for power supply.
• Strap and safety rope for secure handling.
• OLED screen to display various data and settings.
• Automatic retraction of the piston when maximum operating pressure is reached.
• Miniature two-stage hydraulic system for efficient crimping.

Technical Data

The technical specifications of the product are as follows:

• Product number: G9634
• Maximum output force: 120KN
• Stroke: 42mm
• Crimping capacity:   Max. 400mm²
• Oil volume:   About 160ml
• Ambient temperature: -10～40℃
• Battery: DC 18V 3.0Ah lithium battery (a higher capacity battery is optional)
• Crimping cycle : 5 ～ 15 seconds/time (according to the diameter of the terminal)
• Crimping times per saturated battery: About 120 times (Cu150mm²/new battery) (for reference only)
• Charger: AC 220V, 50～60Hz
• Charging time: About 40 minutes
• Tool size: 412 mm×78 mm×326 mm

Standard hexagonal die size:
6, 10, 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300, 400 mm2

If you ask for a special size or special shape, please contact the distributor or manufacturer, they can make the die according to detail requirements.

Safety precautions

Operation safety

• Keep the work area clean and bright, chaos or insufficient light may cause accidents.
• The tool is not insulated and should not be used for live conductors.
• Do not use or store tools around high temperature or corrosive liquids. Pay attention to the deterioration of the sealing components.
• When operating hydraulic tools, do not point your tools’ head towards other people. Children and bystanders should not be close. Distractions during work may cause the tool to lose control.
• Maintain a high degree of vigilance when operating tools, fully grasp the situation, and perform operations with normal judgment. Do not use tools when you are tired or after taking medication or drinking alcohol. A momentary negligence may cause a series of personal injuries.
• Use safety equipment. Always be equipped with masks, goggles, safety helmets, insulated shoes, etc. to reduce the risk of personal injury.
• Dress appropriately. Do not wear loose clothing or jewelry. Keep hair, clothing corners and gloves away from rotating parts. Loose corners of clothing, jewellery, or long hair may be twisted into rotating parts.
• Maintenance of hydraulic tools. Check the calibration and connection of the rotating parts, whether there are any abnormalities in each part, and other conditions that are sufficient to bring adverse effects to the work. If it is damaged, it must be repaired before it can be used.

Please use the tool correctly, and do not put your fingers on the tool head during operation to prevent severely pinching your fingers.

Electricity safety

• The power plug of the charger must match the socket, and the plug must not be modified in any way.
• Do not expose the charger, battery and tools to work in rain or humid environment. Water entering the electrical system will increase the risk of electric shock.
• Do not abuse the wire, never use the wire to carry, pull the charger or unplug its plug. Damaged or entangled wires increase the risk of electric shock.
• If the charger is severely impacted or dropped on the ground or damaged in any other way, please do not use it or disassemble it, and hand it to qualified maintenance personnel. Using a damaged charger may cause electric shock or fire.
• Do not charge the battery when the temperature is lower than 10°C or higher than 40°C, and do not cover or block the cooling holes of the charger and battery during charging.
• In the event of thunderstorms and lightning, please unplug the charger.
• Do not short-circuit or burn the battery to avoid explosion. Note: When not in use, store tools out of the reach of children and other people who are not familiar with tools.

Operating Instructions

Instructions for battery charging
It is recommended to fully charge the Li-ion battery every 2 months. Follow these steps to charge the battery:

1. Connect the charger to a power source.
2. Insert the battery into the charger.
3. Wait for the battery to fully charge. The charging time is short due to the fast charging capability of Li-ion batteries.
4. Once fully charged, remove the battery from the charger and insert it into the tool.

Charger Indicator light:

1. Green light flashes – power on
2. The red light is always on – charging status (below 80%)
3. The red light and the green light are always on – charging status (above 80%)
4. The green light is always on – 100% full
5. Flashing red light or flashing red and green lights at the same time – charger or battery failure

Note:

• The battery can be charged and discharged hundreds of times, but it will eventually fail. When the number of times the tool is used is significantly reduced, replace the battery. Please charge the battery in time, and do not drain the battery completely, as this will cause permanent failure of the lithium battery.
• When the tool is left unused for a long time, self-discharge will also occur inside the battery. You should remove the battery and keep the battery fully charged every quarter.
• Do not use wires to connect the two poles of the battery, as this may easily cause electric sparks, combustion or even explosion.
• Do not use or charge a damaged battery, otherwise it will increase the risk of electric shock.
• The battery is not allowed to be burnt under any circumstances, otherwise it will cause an explosion.
• When the battery is being charged, do not cover the charger with any objects. If the charger cannot dissipate heat, it may easily cause a fire.
• Please disconnect the power supply when you are not using the charger. This will reduce the risk of injury to children and untrained personnel.
• Do not use the charger in a humid environment, and do not expose it to rain or snow, otherwise, it will increase the risk of electric shock.
• Do not disassemble the battery and charger without authorization. If any failure occurs during use, please hand it over to a professional or manufacturer for repair, continue using it until problem is solved.

Usage of the tool

1. First you have to check whether the battery is charged, if not, you should change the full powered battery to settle on the tool.

2. Select the right dies for the intended application.
   Note: Don’t operate the tool without dies.

3. insert the dies into the “C” opened head by pressing retaining clips. Then the connecting
   material shall be positioned in the crimping head correctly, in order to start the crimping procedure。

4. Pull the trigger to release the safety protection system after the display screen normally displays, put the crimped material between the two dies, pull the trigger to start crimping. The moving end moves to the fixed end die, the two dies are gradually closed.

5. A crimping cycle is terminated when the dies contacted each other and when the maximum crimping force is reached. After the crimping cycle is completed the piston retracts automatically. Afterwards a new crimping cycle can be initiated or the crimping process can be terminated by opening the latch and remove the connecting material out of the head. Note: The crimping process can be interrupted at any moment by releasing the trigger.

To use the tool for crimping, follow these steps:

1. Select the appropriate crimping die for the cable or terminal.
2. Ensure that the tool is fully charged and the battery is inserted.
3. Position the cable or terminal between the crimping dies.
4. Hold the tool firmly and press the trigger to start the motor.
5. Allow the tool to complete the crimping process.
6. Release the trigger to stop the motor.

Description of LED display interface

The OLED screen on the tool displays various data and settings. The interface may include information such as battery level, crimping force, and error messages. Refer to the user manual for a detailed explanation of the LED display interface.

Maintenance and Servicing

Regular maintenance and servicing of the tool will ensure its optimal performance and longevity. Follow the instructions provided in the user manual for maintenance guidelines.

• The tool earns a high precise design, please use it properly and do not disassemble it by unprofessional person, otherwise we will not responsible for the problems cause by above misuse. Or we will carry out repair if the users are willing to pay for the spare parts cost.
• Keep the tools dry. Any water may corrode surfaces, metal or electrical parts. If exposed to water, take out the battery and assemble it after it is completely dry.
• Avoid severe temperature fluctuations. Otherwise it will cause deformation of the plastic shell, shorten the life span, and damage the battery. Please do not use any chemical reagents to clean tools.
• In order to extend the service life, please change the hydraulic oil every year.
• If the tool is not used for a long time, please make sure the piston is in the starting position, clean the tool and apply anti-rust oil. Store in a box in a dry environment.
• The sealing components in the tool will be worn after use. If there is a lot of oil leakage, please contact the after-sales service to replace the sealing components in time.
• The original manufacturer’s standard warranty period is 12 months from the date of delivery except for human reasons.

Packing List

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.

The product comes with the following items:

• Hydraulic crimping tool
• Rechargeable Li-ion battery
• Crimping dies
• Charger
• Sling
• User manual

FAQ (Frequently Asked Questions)

Q: How often should I charge the Li-ion battery?
A: It is recommended to fully charge the Li-ion battery every 2 months to maintain its performance.

Q: What happens if I select the wrong cable for crimping?
A: The tool has a manual retraction feature that allows you to return the piston to the starting position in case of selecting the wrong cable.

Q: What should I do if the warning light flashes and I hear a sound?
A: If the warning light flashes and you hear a sound, it indicates an error. Refer to the user manual for the specific error code and troubleshooting steps.

sales@gazelleindustrial.com
www.gazelleindustrial.com

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