Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176 - TestEquipmentDepot.com
Instruction Manual
Battery Crimping Tool 902-484
Due to continuing improvements, actual product may differ
slightly from the product described herein.
Read this material before
Failure to do so can result in serious injury.
SAVE THIS MANUAL
using this product.
LIMITED 1 YEAR WARRANTY
We make every effort to assure that its products meet high quality and durability standards,
and warrants to the original purchaser that this product is free from defects in materials and
workmanship for the period of one year from the date of purchase (90 days if used as rental
equipment). This warranty does not apply to damage due directly or indirectly, to misuse,
abuse, negligence or accidents, repairs or alterations outside our facilities, normal wear and
tear, or to lack of maintenance. We shall in no event be liable for death, injuries to persons
or property, or for incidental, contingent, special or consequential damages arising from the
use of our product. Some states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation of exclusion may not apply to you. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS.
To take advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the complaint
must accompany the merchandise. If our inspection verifies the defect, we will either repair
or replace the product at our election or we may elect to refund the purchase price if we
cannot readily and quickly provide you with a replacement. We will return repaired
products at our expense, but if we determine there is no defect, or that the defect resulted
from causes not within the scope of our warranty, then you must bear the cost of returning
the product.
The warranty gives you specific legal rights and you may also have other rights which vary
from state to state.
TROUBLESHOOTING
FAUL
T ANALYSIS SOLUTION
1. Dirt, contaminants, etc
in ram area of tool.
Tool
is inoperative
Motor
is inoperative
Motor runs
but tool will not
complete a cycle
Dies stop during
operation
LED glows for 20
seconds
Tool loses oil
(leaks)
2. Tool battery contacts
damaged
3. Tool components worn
or damaged.
1. Low or uncharged
2. Broken
1. Oil level low
2. Air in
3. Cold oil
1. Oil level low
2. Air in
1. Battery charge low 1. Charge or replace battery
1. Damaged
internal seal
battery
switch components
hydraulic system
hydraulic system
1. Clean tool
2. Reform contacts
3. Return tool to manufacturer or
distributor
1. Check charge of battery.
Inoperative battery may be
discharged or may have
reached life expectancy
2. Return tool to manufacturer or
distributor
1. Return tool to manufacturer or
distributor
2. Return tool to manufacturer or
distributor
3. Store tool in warm area.
1. Return tool to manufacturer or
distributor
2. Return tool to manufacturer or
distributor
1. Return tool to manufacturer or
distributor
SAVE THIS MANUAL
Keep this manual for the safety warnings and precautions, assembly, operating, inspection,
maintenance and cleaning procedures. Write the month and year of purchase. Keep this
manual and the receipt in a safe and dry place for future reference.
IMPORTANT SAFETY INFORMATION
In this manual, on the labeling, and all other information
provided with this product:
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
GENERAL SAFETY RULES
TO WORK IN SAFE CONDITIONS WITH THIS TOOLING, IT IS IMPERATIVE TO
READ CAREFULLY THE DIRECTIONS FOR USE AND TO FOLLOW THE
INSTRUCTIONS IT CONTAINS. IF YOU DO NOT RESPECT THE INFORMATION
WRITTEN IN THAT INSTRUCTION MANUAL THE WARRANTY WILL BE
CANCELED.
1. Work area safety
a. Keep work area clean and clear. Cluttered or dark areas invite accidents.
b. This tool is not insulated; please do not use it on live conductors.
c. Please do not use or store the tool under high temperature, or one filled with
corrosive fluid. Pay attention to the sealing kits becoming aged and worn out.
d. Keep children and bystander away while operating the battery powered crimping
tool. Distractions will cause you to lose control.
e. Do not use or charge the tool around flammable, explosive environment
2. Electrical safety
f. Make sure the plug matches with the plug socket. Never make any changes on
the plug.
g. Do not put tool, battery and charger in rainy or humid surroundings, it is easy to
trigger an electric shock accident if any water gets into the electric system of the
tool.
h. Do not use electric cord to carry, pull, or to pull out the plug and do not connect
the “-” to “+”, damaged or twisted wire may cause an electric shock accident.
i. If the charger was dropped or crashed to the floor, please do not try to repair it by
yourself, send it back to the authorized service center as soon as possible. The
damaged charger may cause an electric shock accident.
j. If the tool not used for a long time, please make sure the piston stays on its starting
position, clean up the tool and rub rustproof oil both to the tool and accessories. Take
out the battery and put it into the box and store the tool in a dry surrounding.
MAINTENANCE AND SERVICING
Damaged equipment may cause serious personal injury. Do not use damaged
equipment. If abnormal noise or vibration occurs, have the problem corrected before
further using.
1. Before each use, inspect the general condition of the tool. Check for loose screws,
misalignment or binding of moving parts, cracked or broken parts, or any other
condition that may affect its safe operation.
2. After using, clean external surfaces of the tool with clean, moist, rub rust preventing
oil on the metal surface of the tool and the dies to avoid rusty. Store the tool in the dry
environment.
3. Service to the tool should only be done by a qualified Service Technician.
4. In order to prolong the life of the tool please change the oil per year. Make sure the oil
filtered by 120 mesh net or over 30µm strainer. Meantime avoid the dusty into the oil
cup.
5. After a long time using, the sealing kits will be damaged, if there is leakage please
contact with the manufacturer and/or the distributor to change the sealing kits.
j. The best temperature for charging is between 10℃-40℃. Make sure the air hole
of the battery and charger are uncovered during charging.
k. Please cut off the power of the charger each time to reduce the hazard from child
or the person who not expert on the tool.
l. Do not wait until the battery runs over for recharging, the recharging will caused
the battery does not working anymore. Please keep the battery out of the tool to
avoid the power discharge.
m. Please do not burn the battery or make it being short-circuited, it may cause
explosion.
n. Do not use the waste battery otherwise it will caused the electric shock.
o. Do not disassemble the battery and charger. If any problem please contact with
manufacture or agent.
3. Personal safety
p. Stay alert, watch what you are doing and use common sense when operating the
tool. Do not use the tool while you are tired or still under the influence of drugs,
alcohol or medication. A moment of inattention may result in series personal
injury.
q. Use safety equipment. Always use safety equipment such as mask, helmet, safety
cap, insulating shoes and etc to reduce the risk of personal injury.
r. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing
and gloves away from moving parts. Loose clothes jewelry or long hair can be
caught in moving parts.
s. Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the tool operation. If
damaged, have the tool repaired before use. Many accidents are caused by poorly
maintained power tools.
t. Please use the tool properly, the tool with correct power will do the job better and
safer at the rate for which it was designed.
u. Do not put your fingers into the head of the tool during operating. Your fingers
could be pinched very severely.
4. Service
Have your Battery Crimping Tool serviced by a qualified service technician using
only identical replacement parts. This will ensure that the safety of the Battery
Crimping Tool Kit is maintained.
SPECIFIC SAFETY RULES
1. Maintain labels and nameplates on the tool which carry important safety information.
If unreadable or missing, contact the agent to replace.
2. This product is not a toy, keep it out of reach of children.
3. Do not put your fingers into the head of the tool during operating. Your fingers could
be pinched very severely.
4. Make sure the head was locked firmly during operation.
5. Do not use the tool without dies
6. Do not crimp on live cables or conductors
7. Do only crimp copper or aluminum conducting material
8. Do not knock any parts of the tool, otherwise it will cause injury.
9. Do not operate at will, it will damage the MCU and electric system
10. The design of the limit screw on the head is for preventing the head from dropping or
popping.
11. Make sure the head was locked firmly during operation.
12. Do not use this tool for continuous use. After 30 to 40 cycles, allow the tool to cool for
15 minutes.
13. Do not secure this tool in a vise. This tool is designed for hand-held operation.
14. The built-in safety valve goes through strict pressure test before marketing; please do
not adjust the pressure by unprofessional person. If the pressure is not enough please
return the tools back to the service center. The tool only can be reused after checking
and testing by trained person.
15. The warnings, precautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be
Make sure that all the parts are clean without any oil, dust, especially on the
handle and control parts, to avoid the tool drop easily during the operation.
1) 1) First press the for 3 s to turn on the power, the tool will self-test for 1 s,
the data showing the last record, the tool is ready to work.
Inspect the battery to see if it is charged or run out.
2) Select the right dies for the intended application,
Don’t operate the tool without dies.
the crimping head has to be opened by pushing the Latch, insert two dies top and
bottom, the steel ball located center of the die will match the hole of the latch and die
holder when both die halves are in place. Then the connecting material shall be
positioned in the crimping head correctly, in order to start the crimping procedure,
3) A crimping process is initiated by switching the trigger. It is defined by the closing
motion of the dies. The connection material is positioned in the stationary half of the
crimping dies and the moving part is approaching the compression point.
4) 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 removing the connector
material out of the head.
understood by the operator that common sense and cau
be built into this product, but must be supplied by the operator
are factors which cannot
tion
.
UNDERST AND YOUR TOOL
902-484 is a tool for crimping Cu lugs with cables from 16-400 mm2. It is powered by
Li-ion, actuated by motor and controlled by MCU. With a high pressure hydraulic system,
LED light, LCD , error warning alarm, pressure showing..etc function, it is a perfect tool to
be used in electrical construction site.
1. Specification
Max. crimping force: 6 Ton
Crimping range: CU AWG 6 to 600MCM
Stroke: .67 inch
Crimp/Charge 320 times(Cu 300MCM)
Time/crimp: 3-6s( depend on the size of cable)
Hydraulic oil: Shell Tellus T15#
Capacity: 115ml
Ambient temperature
Voltage: DC 18V,3Ah
Charging voltage:
Charging time: Approx.2 hours
-10-40℃
AC 100V～240V ;50～60Hz
The crimping process can be interrupted at
button.
Do not put your fingers into the head of the tool during operating. Your fingers could
be pinched very severely.
any moment b
y releasing the trigger
Accessories:
Crimping die: 6,4,.2,.1/0.2/0.3/0.4/0. 300,350,500,600MCM
Battery: 2 pcs
Charger: 1 pc
Sealing ring of cylinder: 1 set
Sealing ring of safety valve. 1 set
2. Description of components:
Set the output
force
Press for 3 s enter into setting status, the data display
will flash. Press the per time, output data increase by
10 KN (1Ton) (or 5 KN (1.2 Ton), according to requirement),
this action is circulated from Min KN to Max KN. Press
for 3 s or leave it 15 s, it returns to initial state.
Parts No. Description Function
1 Die holder For fixing die
2 Die For crimping, interchangeable die
3 Latch For locking /unlocking the crimping head
4 Die holder For fixing die
5 LCD
6 Keyboard For power switch, function switch, LED light switch
7 Limited screw For prevent head from dropping or popping
8 LED indicator For lighting
9 Trigger
10 Lock Locking the battery
11 Battery
Showing the data (crimping times, electricity
capacity, error information)
For operating or retracting the piston in case of
incorrect operation.
For supplying power, rechargeable Li-ion（18V）.
LED
Battery power
Convenient in dark environment, with a light symbol showing
on the LCD, through to get into start status.
display, and lighting. LCD background lighting, meanwhile
press the power button, the front LED lighting, after 20 s, the
light turn off automatically. During LED lighting, keep for
pressing to turn off the LED even for the LCD
background light.
full power.
, meanwhile flash and buzzing according to the flash
frequency . Charge the battery.
Error showing Error occured, such as motor damaged, drive system error and
hydraulic system problem… the tool stop working. LCD
showing “error data” as following: it stands for “over power
capacity”
Power off
USB port with
computer
Press for 3 s or leave the tool 30 s to off the power
Take the battery away from the tool, connect the USB with a
computer to exchange the data. LCD showing symbol
The battery can be charge cycled hundreds of times, when the charge time is reduced
considerably, change to a new battery.
Please charge the battery in time to avoid it to be used up completely; otherwise it will
become useless forever. If the battery not be used for a long time, it will discharge
automatically, so take it out of the tool and make sure to charge it one time per/each
quarter.
2. Usage of the tool
3. Function description
MCU –automatically detect the pressure during operation and provide
Security protect, shut off the motor and reset automatically after
operation.
Auto reset- Release the pressure automatically, retract the piston to the
starting position when reached the max output.
1. LCD board instruction:
2. LCD board showing and setting:
Please note: tool in power off , there is no any data showing.
Power on
Press for 3 s, the tool into starting status, the
keyboard showing all the data for 1 s, then the tool is self
inspecting for 1 s. the data will be changed and increased in
order
Exchange
showing
In the power on status, press , the data exchange
One key control- press the trigger to start working, half pressing the trigger
means stop forcing pressure, letting go fully means piston returns to the
original position.
The unit is equipped with a double piston pump which is characterized
by a rapid approach of the die towards the connector and a slow crimping
motion.
The head can be smoothly turned by 350° around the longitudinal axis
in order to gain better access to tight corners and other difficult working
areas.
Suspend—finish working or withdraw the hand from the trigger or any
accident happened, the device inside of the tool can stop power supply.
One significant sound will be heard and a red display flashes if any error
occurs or lower power being.( Ref. table 1)
Per time pressing on the trigger, the LED will lighting for 20 seconds.
High-performances Li-ion battery in strong power supply, No discharge
memory effect., Ultra lower power consumption standby design keep the
tool 6 months storage, meanwhile over discharge device prolong the life
span of the battery.
A temperature sensor makes the tool stop working automatically when
the temperature over 60˜ under long time working, the fault signal
Table 1.
Series
No
1
sounds, it means the tool can’t continue working until the temperature
reduced to normal.
Micro computer control system with the feature of self-pressure detecting,
double protection during operation, counting and realize the exchange
between computer with data by the converter.
Error code
On ---
Instruction What it means
Self-checking
Self-checking to assure
everything is ok
OPERATING INSTRUCTION
Read the entire SAFETY INFORMATION section at the beginning of this manual
including all text under subheadings therein before using this product.
Use this tool for the manufacture’s intended purpose only. Use other than that which is
described in this manual can result injury or property damage.
1. Charging
Push battery into charger and connect the plug with the plug seat. Make sure the room
temperature is between 10˜ -40˜ 。The charging time is around 2 hours. Please see the
Hydraulic system may
2
E01
3
4
5
E02
6
E03
7
E04
●●●
●—5sec
●●●●
●●●●●
Overload
Charging
signal
Po
wer lacking
warning
Sensor error
Temperature
warning
No pressure
be damaged and need
checking immediately
Lack
ing power and
needs charging.
No power and needs
charging immediately
Temperature sensor and
power inspecting error
Temperature too high,
tool need to be cooled
Motor working but
without pressure
illustration below.
The detail of the charging information, please refer the manual (MANUAL
CHARGER)
FOR
Test Equipment Depot - 800.517.8431 - 99 Washington Street Melrose, MA 02176 - TestEquipmentDepot.com
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