GAZELLE G9636 Hydraulic Crimping Head User Manual

GAZELLE G9636 Hydraulic Crimping Head

Specifications

• Warranty: 1 year for main unit, 90 days for parts and accessories
• Operating Temperature: -20°C to +50°C
• Crimping Range: 10-400 mm² to 25-185 mm²

Product Usage Instructions

Description of the Hydraulic Crimping Unit

• The hydraulic crimping unit consists of a coupler and components for the crimping procedure.

Description of the Crimping Procedure

• The crimping process involves positioning the cable lug or connector in the stationary half of the crimping die. The piston then pushes the moving part of the die towards the compression point until maximum pressure is reached.

Operation of the Unit

1. Select the appropriate dies for the application.
2. Connect the crimping head to the high-pressure hose and unroll it completely.
3. Insert the dies laterally and position the crimping head.
4. Start the pump until the dies are fully closed.

Follow the steps outlined in section 4.2 for the crimping process. Once completed, retract the piston and remove the connecting material from the crimping head.

Mounting Instructions

Refer to Table 3 for marking of dies to ensure correct usage based on material type.

FAQ

Q: What is the warranty period for the GAZELLE Hydraulic tools?

A: The warranty period is one year for the main unit and 90 days for parts, accessories, product repairs, and services.

Q: What is the recommended operating temperature range for the hydraulic crimping unit?

A: The tool can be operated in a temperature range from -20°C to +50°C indoors and outdoors.

Introduction

• Before starting to use the tool please read the instruction manual carefully.
• 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 instructions should be kept properly during the entire lifetime of the tool. Visit www.gazelleindustrial.com to download the digital copy of the user manual.
• The operator must guarantee the availability of the instruction manual for the user and 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, the name of the manufacturer, and the company logo. The serial number is on the hydraulic cylinder.

Warranty

• Each GAZELLE Hydraulic tool is warranted to be free from defects in material and workmanship under normal use and service unless stated otherwise herein.
• The warranty period for the main unit is one year and begins on the date of purchase. Parts, accessories, product repairs, and services are warranted for 90 days unless otherwise stated.

Description of the hydraulic crimping unit

Description of the components

Description of the crimping procedure

• A crimping process is characterized by the closing motion of the dies. The cable lug or connector will be positioned in the stationary half of the crimping die. The piston will push the moving part of the die towards the compression point.
• The crimping process is complete when the dies contact and the maximum operating pressure of the pump is reached.

Remarks concerning the determined use

• The pump must be positioned on an even surface with a max. angle of 15°. Operating of machine on an uneven surface can affect the performance of the device.

Operation of the unit

1. First, you have to select the right dies for the intended application. Then connect the crimping head to the high-pressure hose and roll out the hose completely.
2. Insert the dies laterally and bring the crimping head into position.
3. Start the pump until the dies are completely closed.

• The crimping process will proceed as described in Chapter 4.2.
• After the crimping process has been completed and the piston has been retracted, remove the connecting material from the crimping head.

Explanation of the application range

Table 2

DIN 48201, sheet 6 and Al-conductors ACC. to DIN 48201, sheet 5,120-300 mm2
25/4-120/20| Compression joint acc.to DIN 48085 part 3 for Al-/Steel cables acc.to DIN 48204
10-240 sm 35-300se| Pre-rounding dies for Al-and Cu-Sector conductors
10-50| Solderless Terminals DIN 46234, Pin terminals DIN 46230
10-150| Insulated Terminals
16-300| Tubular cable lugs for fine-stranded conductors
4-50| C-clamps
10-150| Pre-insulated tubular cable lugs and connectors, insulated pin cable lugs
2×50-2×120| Double compression cable lugs
25-185| Cable-End sleeves

Attention

• Only crimp copper and Aluminum connecting materials or special connecting materials which are mentioned in Table 2.
• If different conducting materials need to be crimped, please contact the manufacturer.
• Attention: Do not use on or near live circuits.
• Before starting to crimp please make sure that all parts involved in the crimping process are not connected to live circuits.
• The tool can be operated in a temperature range from -20℃ to +50℃ indoors and outdoors.

Mounting instructions

Table 3 Marking of the dies

 | Dies| Marking Outside| Marking crimping profile| The surface of the dies| Crimping Width

「 mm 」

---|---|---|---|---|---
a| “Standard type”| CU,” QS”| ”QS”| chrome plated, yellow| 10-20
b| DIN 46235/ DIN 46267| CU,” QS”, DIN 46235| code number| chrome plated, yellow| 10-17
c| Aluminum| AL,” QS”,| code number| blue zinc| 12-17
d| Compression joint| AL,”QS”,| code number| blue zinc| 12-14
e| Compression joints DIN 48085| AL, QS ST, QS| code number| blue zinc blue zinc| 10-15 14
f| Terminals DIN 46234/46230| CU; QS, DIN 46234| ”QS”| chrome plated, yellow| –
g| Insulated terminals| ISQ,QS| ”QS”| chrome plated, yellow| –
h| Tub.CL for fine-str. conductors| F,QS| ”QS”| chrome plated, yellow| –
i| C-clamps| C,QS| –| chrome plated, yellow| –
j| Pre-insulated tub. CL and connectors| IS,QS| ”QS”| chrome plated,

yellow

| –
k| NI-TCL、C| QS|  | chrome plated, yellow| –
l| Cable-end sleeves DIN 46228| AE,QS| –| chrome plated, yellow| –
m| Double WF| AE,2×QS| –| chrome plated, yellow| –
 | WF Compression neutrons conductor| AE,QS| –| chrome plated, yellow| –
24- 216| Double Compression neutron conductor| AE,2×QS| –| chrome plated, yellow| –

• Abbreviations: CL-tubular cable lugs, AEH-cable end-sleeves, QS-Cross-section
• If applications other than those mentioned in Table 2&3 are intended to be performed with this tool it is necessary to contact the manufacturer.
• With those dies mentioned in Table 3a only connectors “Standard type” are supposed to be crimped. Crimping of commercial cable lugs and connectors of other suppliers will not result in a perfect crimp.
• The same is valid for conducting material table 3j. No guarantee can be given for crimping C-clamps of other suppliers.
• Despite the same code numbers, the compression width for copper and aluminum cable lugs and connectors is different. Besides the marking of the dies the surface plating also differs.

Attention

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

Service and maintenance

• The hydraulic tool must be cleaned and dried after each use. The tool is maintenance-free. After one year we recommend sending the tool in to the manufacturer for an inspection.
• Within the determined use of the tool, only the dies (Pos.-No.2+3) are permitted to be changed by the customer.
• Do not attempt to repair the tool yourself, and do not remove any parts such as screws and other components.

Troubleshooting

• The tool loses oil.
• Return the tool to the manufacturer. Do not open the tool.

Technical data

• Crimping force: 250kN
• Stroke: 20mm
• Rated pressure: 700bar
• Crimping capacity: Max Cu 630mm²/ Al 500 mm²
• Weight: 5.5kg
• Dimensions: 361313cm

Symbols

• Safety warnings
  • Please do not disregard these instructions to avoid human injuries and environmental damage.
• Operational warnings
  • Please do not disregard them to avoid damaging the pump unit.
• 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.
• GAZELLE
• sales@gazelleindustrial.com
• www.gazelleindustrial.com

Documents / Resources

| GAZELLE G9636 Hydraulic Crimping Head [pdf] User Manual
G9636, 16-630mm, G9636 Hydraulic Crimping Head, G9636, Hydraulic Crimping Head, Crimping Head, Head
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References

• acc.to
• Gazelle® | Jobsite Tool Solutions & Electrical Test Tools

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