Gazelle G9622 User manual

Contents
1. Introduction.............................................................................................................. 1
2. Labels ........................................................................................................................ 1
3. Warranty .................................................................................................................. 1
4. Description of the hydraulic crimping unit ........................................................... 1
5. Remarks in respect of the determined use............................................................. 2
5.1 Operation........................................................................................................... 2
5.2 Explanation of the application range ................................................................ 2
5.3 Mounting instructions ....................................................................................... 4
5.4 Service and maintenance instruction ................................................................ 4
5.5 Storage and transport of the crimping tool ....................................................... 4
5.6 Reference as to which spare parts can be exchanged by the customer.............4
6. Troubleshooting ....................................................................................................... 4
7. Putting out of operation/wasted disposal...............................................................5
8. Technical Data..........................................................................................................5

1
1. 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.
2. 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.
3. Warranty
If correct operation is guaranteed and regular service is provided our warranty is 1
year from the time of delivery.
4. 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:
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 in to starting position
5
Guiding handle
To guide and position the tool

2
6
Turn screw
To activate the transportation lock
5. Remarks in respect of the determined use
5.1 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.
5.2 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
Crimping range
Crimping dies
Marking
Profile
Surface of
Width

3
mm2
outside
the dies
6-300
TCL and C.
Standard Version
CU, ,,QS“
,,QS“
Chrome
plated
(yellow)
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
10-240sm
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)
-
10-70
Insulated terminals
ISQ, QS
,,QS“
Chrome
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“
Chrome
plated
-
2×50-2×70
Double CL
DP, QS
,,QS“
Chrome
plated
5mm
10-50
Ni-Cl and connectors
NI, QS
-
Blue zinc
5mm
10-70
Oval connectors
CU or AL
QS
code #
Chrome
plated
5mm
10-185
WF DIN 46228
AE, QS
-
Chrome
plated
-
2×4-2×16
Double WF
AE,2×QS
-
Chrome
plated
-
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.

4
5.3 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.
Attention:
Even if the code number is identical only those dies should be used which
are suitable for the material.
5.4 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.
5.5 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.
5.6 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.
6. 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.

5
7. 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).
8. 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: 56*17*7cm
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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