GAZELLE G9622 Hand Hydraulic Crimping Tool User Manual

: June 27, 2024
: GAZELLE

Table of Contents

GAZELLE G9622 Hand Hydraulic Crimping Tool
Specifications
Introduction
Warranty
Remarks with respect to the determined use
Troubleshooting
Putting out of operation/wasted disposal
Technical Data
FAQ
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GAZELLE G9622 Hand Hydraulic Crimping Tool

Specifications

Model: Hand-Hydraulic Crimping Unit G9622
Function: Crimping tool
Components: Dies, Crimping head, Pump handle, Retract lever, Guiding handle, Turn screw
Warranty: 1 year from time of delivery with correct operation and regular service

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 guarantee 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 G9622 is a hand-held tool and consists of the following components:

POS.- NO.	Description	Function
1	Dies	Crimping
2	Crimping head	120KN C-shape head for wide crimping

dies

3| Pump handle| To operate the pump
4| Retract lever| To activate the pressure relief valve and to return the dies to the starting position
---|---|---
5| Guiding handle| To guide and position the tool
6| Turn screw| To activate the transportation lock

Remarks with respect to the determined use

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

Attention: Don’t use the tool without dies

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. To start the crimping procedure, the turn screw must be turned 180°while the pump lever is pushed towards the handle.
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.
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.
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 in the handle force.
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.
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 for crimping primarily copper and aluminium but other connecting materials.

Table 2

Crimping range mm2|

Crimping dies

| Marking outside|

Profile

| Surface

of the dies

| Widt h
---|---|---|---|---|---

6-300

| TCL and C. Standard Version|

CU, ,,QS“

|

,, QS“

| Chrome

plated (yellow)

|

5mm

6-240

| TCL and C. DIN46235/DIN4626

7

| CU, ,,QS“

DIN46235

|

code#

| Chrome plated

(yellow)

| 5mm
10-240| Aluminum CL and

C.

| AL, ,,QS“| code #| Blue zinc| 7m

m

25-185

| aluminium C. High-strength

aluminium wire

|

AL, ,,QS“

| code #| Blue zinc| 7m m

25/4-120-20

|

Full tension C.

| AL, ,,QS“| code #| Blue zinc| 7m

m

ST, ,,QS“| code #| black| 5mm

10-240sm

35-300se

|

Pre-rounding dies

| RU； QS， sm；

QS，

sm；

| –| Chrome plated (yellow)| –

10-70

| Terminals DIN46234/46230| CU, ,,QS“

DIN46234

| ,, QS“| Chrome

plated (yellow)

plated

| –
10-70| Tub.CL.for fine-str.

conductors

| F, QS| ,, QS“| Chrome

plated

| –
4-50| C clamps| C, QS| –| Chrome

plated

| 5mm

10-150

| Pre-insulated

tub.CLT and connectors

|

IS, QS

|

,, QS“

plated

| 5mm
---|---|---|---|---|---
10-50| Ni-Cl and

connectors

QS

| code #| Chrome

plated

plated

plated

| –

Attention: Do only crimp copper and AL conducting material or special connecting material mentioned in Table 2.
Do not crimp on live cables 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 aluminium cable lugs and connectors is different. Besides the marking of the dies the plating is different too

Attention: 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 maintenance-free, only the bolt joints have to be oiled regularly.

Storage and transport of the crimping tool
To protect the tool against damage it has to be cleaned carefully after every use and be put into the transportation case which has to be closed 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 the customer.

Troubleshooting

The dies came to a standstill during the crimping process respectively the crimping tool didn’t reach the final operation pressure.
=>Actuate the pump lever and simultaneously push the retract lever.
The tool loses 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 groundwater.
Uncontrolled draining of or improper disposal is under penalty (environmental liability law).

Technical Data

The crimping head can be turned 360°in a pressure-free state.

Weight of the crimping tool: 700 bar
Crimping force: Max 400mm²
Stroke: Standard dies:
Rated pressure: Dimension:
Crimping capacity:
6.1KG: Cu6-400mm²
120KN: 56177cm
42 mm

WARNING: We shall in no event be liable for death, or injuries to persons or property from the improper use and lack of maintenance of our product. Any doubt about safety operations and precautions, please contact our distributor.
Please properly dispose of all packing materials and remove parts.

sales@gazelleindustrial.com
www.gazelleindustrial.com

FAQ

Q: Can this tool be used with materials other than copper and aluminum?
- A: The tool is designed for primarily copper and aluminium materials as mentioned in Table 2. Contact the manufacturer for other materials.
Q: What should I do if I need to perform an application not listed in the table?
- A: Contact the manufacturer for guidance on using the tool for applications not specified in Table 2.