Crimping pliers for wires. Crimping tools for cable lugs. Main types of mites

For quality connections various wires and cables with sources and consumers of electricity, metal crimp lugs and sleeves are used. Their fastening at the ends of wire products is carried out using a press tongs for crimping the tips.

Features of crimping pliers

The principle of operation of the tool is similar to the work of pliers. Crimping pliers for ferrules are distinguished by the complex profile of the pressing jaws. Crimping pliers or crimpers have various sizes and the shape of the landing bed. Each type of tool is designed for crimping wires and cables with a certain cross section and number of cores.

Tools for crimping wire lugs and cable cores allow you to quickly and efficiently carry out switching connections between power units. The crimping process for cable lugs is quite simple. A sleeve is put on the bare end of the wire or stranded twist. She is led into the opening of ticks. With the force of the fingers, the levers of the tool are squeezed, and the crimper compresses the sleeve with the wire.

Main types of mites

Crimping pliers are divided into two types. The most common type is a design that works like pliers. That is, the sleeve is compressed on both sides. Other pliers are diaphragm crimpers.

pliant

The tip is crimped in the same way as pliers capture any part. Working surface matrices has cutouts into which the tip shank is threaded. This design is suitable for those fasteners that do not need special reliability.

To increase the crimping force, hydraulic ferrule crimping tools were invented. Thanks to this improvement, the pliers began to have greater application efficiency. The design uses cylinders with pistons filled with oil, which creates a large pressure of the dies on the tip sleeve.

Important! Some crimpers are equipped with several types of removable dies. The versatility of the tool eliminates the need for pliers for each size of conductor section.

The originality of the design of diaphragm crimps lies in the comprehensive coverage of the tip shank. The principle of operation is similar to the movement of the aperture blades of photographic lenses. The only drawback of such devices is the impossibility of inserting ticks into the connection of the two ends of the wires.

Note! A diaphragm tool is used as a press for metal tips of a pin or flat shape. The all-round clamp is much more effective than the pliers type of coverage of the wire products.

Application area

Crimping pliers for wire lugs of certain designs are used depending on the cross-sectional composition of cable products. The main areas of use of crimpers can be represented by the following list:

• stranded wires and thin-walled lugs;
• stranded wires and thick-walled lugs;
• tips and electric cable large section;
• sequential crimping of wires;
• crimping computer cables.

Stranded wires and thin-walled lugs

Thin-walled lugs are used for wires of small cross section - from 0.5 to 3.5 mm2. Elements are marked NShVI. The abbreviation stands for:

• H - tip;
• Ш - pin;
• B - sleeve;
• And isolated.

NShVI tips are used for crimping copper stranded wires followed by insertion into the sockets of various electronic devices. The handles of the crimpers are compressed until the spring mechanism of the device is activated.

Note! Multi-stage matrices of clamps allow you to work simultaneously with wires with a cross section in the range indicated above. This eliminates the need for a large number of staple crimping hand tools.

Press tongs create a strong and reliable crimping of the tips. Without them, one would have to twist stranded cores or solder switchgear terminals. The use of pressed limit switches completely eliminates the problems associated with the breaking of thin veins, wire breaks, and the risk of a short circuit.

Stranded wires and thick-walled lugs

Thick wall shanks are used for crimping stranded power cables. Their limiting section reaches 16 mm2. Press tongs PK-16 are used only for stranded wires. The tool can compress the sleeve so hard that it will easily break a single core.

The cable crimping process takes place in several stages:

1. At the end of the wire, mark the length of the sleeve.
2. Special wire cutters remove the insulation from the marked area.
3. Put on a piece of heat shrink tubing so that it does not go over the bare wire.
4. The cleaned end of the cable is inserted into the sleeve. The entry of the wire should be tight, but without effort.
5. Pincers crimp the tip.
6. Protruding veins bite.
7. The heat shrink tube is heated with a hair dryer until it tightly wraps around the cable.

If the letter “U” is indicated in the marking of the tool, then this means the location of the ratchet mechanism inside the handles, which creates a large force on the jaws of the crimper. Pliers PK-16-U are more easily compressed during cable crimping.

Lugs and heavy gauge electrical cable

Crimp for ferrules electric cable large section is produced by a manual hydraulic press. Initially, the valve of the device is ajar, and the stem slowly moves to its original position. At the beginning of the piston stroke, the valve opens completely, which ensures that the dies are compressed with great force.

In house equipment large cables are rare. Mostly hydraulic pliers used to install lugs on high-voltage cables for fixing them in shields industrial facilities. Crimping hydraulic pliers for overall ferrules are also used when laying and switching power cables in energy shields of entrances residential buildings, administrative buildings and civil buildings.

The hydraulic press is equipped with cassettes with interchangeable dies. The upper lever is equipped with a magnet, which, after compression, returns the handle to its original position. The levers are equipped with rubberized shells, which ensure the electrical safety of the device. The crimping of two cables with a double-sided sleeve is carried out when transferring the electrical panel. These pliers for simultaneous crimping of two wires are also used when building copper conductors with a diameter of 6-12 mm2.

Consistent crimping of wires

This method is used when connecting pieces of wire into a single whole. This is especially important for sequential compression conductors with conductors of different metals. For example, when you need to make a bow of aluminum and copper wire, use a crimp sleeve.

The fact is that twisting from dissimilar metals will cause destructive processes from their direct contact with each other. The connecting sleeve becomes a kind of bridge between aluminum and copper.

Bare wires are inserted from both sides into the sleeve. After that, the sleeve is squeezed with tongs. The compressed sleeve does not allow air to enter the connection, which prevents the occurrence of oxidative processes in the metal of the wires.

Crimping computer cables

Often the question arises of crimping an Internet cable to connect it to a computer or to combine several PCs with a local network. For this, a twisted pair cable is used. The wires are untwisted and distributed parallel to each other. At the same time, the strict color arrangement of the wires is observed.

RJ-45 plastic connectors are used as tips. Polymer tips are intended for insertion into the nests of hubs and network adapters. A twisted pair consists of eight wires. Interlaced in pairs, insulated cores minimize interference when electric currents pass through them.

Special crimpers are used to crimp the ends of cables. The RJ-45 connector is a plastic box with a hole for the cable on one side and contact terminals on the other side.

The process of installing connectors on network cables is as follows:

• remove one centimeter of insulation, for this there is a special connector on the pliers;
• twisted pairs are untwisted, aligned in a certain order;
• wire cutters evenly cut the wires so that the bare ends of the wires are formed;
• the wires are inserted into the RJ-45 connector, the cut wires with their cores should be tightly adjacent to the back side of the terminals;
• the plastic connector is inserted into the opening of the pliers, then the tool handles are squeezed.

Twisted-pair wires should run from left to right in next order(view from above from the side of the entrance to the connector):

1. White-orange.
2. Orange.
3. Green-white.
4. Blue.
5. Blue white.
6. Green.
7. White-brown.
8. Brown.

How to work with crimping pliers

Self-mastery of crimping tongs may initially be accompanied by the creation of a poor-quality connection of the sleeve or tip with the wire. It often happens that a seemingly reliable crimp hides a bad contact. This can happen for two reasons.

If the shape of the terminals is not maintained

Mismatch between the size of the tip or sleeve with the opening between the jaws of the dies can cause a distortion of the squeezed element. Before proceeding with crimping, you should try on the tip to the opening in the tongs. It is also important that the bare end of the wire fits tightly into the holes of the shank or sleeve.

A bundle of wires or a single core should enter the connecting element with a slight stretch. If there are any doubts about the reliability of fastening, it is worth practicing on separate sections of the cable. After crimping by hand, you need to check the strength of the connection. At the slightest backlash, the crimp should be rejected and crimping should be resumed with another limit switch.

Excessive clamping can damage the strands inside the sleeve. The accompanying documentation of crimping pliers usually indicate the cross-sectional dimensions of the lugs directly for each opening of the pliers. Soft metal alloy connectors should be avoided. Over time, the tip may lose strength, and the contact will become unreliable.

Twisting stranded wires before crimping

The error can be made by the habit of twisting the strands, which is done before insulating or soldering hand connections. It is absolutely impossible to do so.

You can check the perniciousness of twisting in a simple way. It is worth squeezing the twisted stranded cables with pliers to make sure that the wires are deformed and damaged.

If, when removing the insulation from the installation section of the cable, twisted conductors are found, then they must be straightened. Only after that, the cores are inserted into the opening of the tip or sleeve.

Tip color coding

Color marking is used for NShVI tips. The color of the connector skirt corresponds to a certain wire section:

• black - 1.5 mm2;
• blue - 2.5 mm2;
• gray - 4 mm2;
• yellow - 6 mm2;
• red - 10 mm2.

Table color coding tips NShVI

Crimping wires with pliers in terms of quality and speed of connections cannot be compared with manual twisting or soldering. For any connection, you can always choose desired model crimper.

Video

When crimping conductors, one of the main conditions for obtaining high-quality contact and its reliable operation in the future is the use of a professional tool. One of these tools is press tongs or crimpers designed for crimping bushings, insulated, not insulated tips and automotive terminals.

Crimpers for automotive terminals and insulated lugs must have dies with a double-circuit crimping profile - along the core and along the insulation. Also, its geometry and shape must match the crimp part of the ferrule.

As a rule, it is best to buy sets at once, where the pliers themselves and all the necessary matrices are included.

Among domestic manufacturers stands out the company KBT and its two sets for crimping:

Consider their configuration, differences and principles of operation. Both of these sets are designed for crimping both insulated and bare lugs.

Press tongs CTB

The CTB set includes:

• press pliers themselves
• five numbered matrices
• plastic case

Press tongs have a mechanism for quick removal and replacement of dies.

Keep in mind that any matrix, like any part, has a run-in property. And during the first few dozen crimp cycles, it is quite possible that the tip may bite.

Sometimes the jam is such that the matrix jumps out of its quick-release mechanism. This does not at all mean a poor-quality tool, and over time, after running in, you will forget about such an inconvenience.

Actually, quick-detachable matrices are of course positive moment, but in practice there is really a lack of some mechanism for their rigid fixation. And the longer you operate the crimper, the more this mechanism is weakened.

Press tongs CTB are made of high quality steel. Equipped with a ratchet mechanism that provides a full cycle of crimping. There is also an asterisk with which you can adjust the clamping force.

In the upper part there is a lever that allows you to unlock the tool from any position.
If you choose the wrong die size and start crimping, the press tongs may not reach the very end, thereby locking the handles in an intermediate position. Here, just the same, you will need an unlock lever.

The handles are elongated, so that it is convenient to crimp with two hands. For relatively large sections and large volume work is very helpful.

Compared to other manufacturers, a small angle of opening of KBT crimper handles plays a significant role. For other models, in order to perform a girth, sometimes you need to have not hands, but large paws. A small angle of wiring allows you to use the tool with much greater convenience and comfort.

Matrices for press tongs

Why do we need as many as 5 sets of matrices? There is not only a difference in the cross section of the crimped lugs, but also in their functionality and size.

For each type of tips, you can choose your ideal option.
In the CTB press tongs, as in the CTF, the dies are interchangeable, which makes these sets absolutely compatible and can significantly save your budget.

Most often, you have to use dies designed for crimping insulated and non-insulated sleeve lugs of the NShVI and NShV brands. The matrix is ​​digitally marked along the cross section of the tip.

These dies are specially designed to form a solid pin at the end of a stranded strand.

To give mechanical strength a special corrugation is applied on the inner surface of the crimping profile.

The MPK-02 model matrix fits the most popular series ferrules section from 0.25 to 6mm2.
And what to do if you have a sleeve end with a cross section of as much as 25mm2? Here you will be rescued by the matrix of the MPK-03 model. This die already crimps insulated and non-insulated ferrules from 10 to 25mm2.

For crimping double end sleeves of the NShVI-2 brand, you need to use the MPK-06 matrix. It has 7 positions and crimps ferrules from 0.5 to 6mm2.

Keep in mind that it does not come with the tool and you will have to buy it separately. You can get acquainted with the current prices and choose a set of matrices for yourself.

There is another way out of the situation. If you need to crimp the double tip of NShVI-2, and there is no way to buy a matrix for it, use the ordinary MPK-02 matrix.

The only condition is that you need to crimp such a NShVI-2 with a connector one size larger.

That is, when you have a double tip with a section of 4mm2 NShVI (2) -4-12, then you need to press it with a matrix designed for a single one under 6mm2.

The set also includes an MPK-01 matrix for insulated connectors of the brand NKI, NVI and the like. It is designed for sections from 0.5 to 6 mm2.

Well, the last two sets of matrices are MPK-04 - for auto-terminals and MPK-05 - for bare copper tips.

The dies are inserted into the pliers in such a way that the side of the die with the smallest section of the crimping profile is always located at the edge of the jaws.

Sleeve tips NShVI this crimper compresses with a trapezoid. Such a crimp profile is quite wide and may cause some connection problems with individual equipment. Keep in mind that when connecting wires to starters of the second magnitude, after crimping wires of relatively large sections with a trapezoid, sometimes you have to put them into contacts sideways.

Press tongs set CTF

This set also includes 5 matrices. True, there is no longer a quick release mechanism.
To replace the matrix, you will have to use a hex key. Which is not very convenient and can take much longer than the compression process itself.

Of course, you can do amateur activities and somewhat modernize the process of removing matrices. To do this, nuts can be soldered onto the factory screws, which are already easy to twist by hand without the use of hexagons and special keys.

Also included are 2 spare screws from the dies in case you lose the current one or ruin the threads on them.

The lack of a quick release mechanism is of course one of the main disadvantages of this tool. Imagine you are sitting in front of a closet, in which there are a couple of hundred conductors. All of them go in order, of different sections and sizes, and they need to be crimped accordingly. How much extra time and nerves it will take you to unscrew and twist the matrices, the question is far from rhetorical.

When inserting dies into CTF pliers, in order not to be mistaken, look at the size of the crimping slot. big size insert in the direction of the handles, with a smaller one - in the groan of the nose of the tool. The vertical positioning of the matrices also plays a role.

A reasonable question arises, why do we need a CTF set with an inconvenient process for replacing dies, if there is a CTB press tongs with a quick release mechanism?

The fundamental difference of CTF is the parallel closure of matrices. This form of crimping is the most important advantage over any other pressing tongs.

When using conventional press tongs, the crimping of insulated and non-insulated ferrules first occurs from one edge, then in the center, and only at the end the ferrule is crimped in its entirety.

But the CTF model has such a design that the jaws on it close in parallel from top to bottom. Therefore, crimping occurs evenly and immediately over the entire surface of the tip.

Parallel closure of matrices provides more high quality connections.

True, it is possible that you picked up the matrix and the tip, it seems, correctly, and the wire after crimping is still poorly clamped inside the sleeve. How is this possible?

And the reason here lies in an unscrupulous cable manufacturer. It is they who can make the wire, relying on their technical conditions, and not on GOST. As a result, the cross section is not 1.5 mm2, but less than 1.25-1.3 mm2. You, however, clamping it all with a 1.5mm2 matrix, naturally cannot achieve the result you need.

On new pliers, nothing needs to be adjusted. The factory settings are set optimal conditions crimping. However, during long-term operation, the matrices can become loose and play and slack appear.

Adjustment is carried out using an eccentric. Unscrew the stopper screw and turn the sprocket. To the plus side, if you need to increase the convergence of the matrices and to the minus side, if, on the contrary, to weaken.

The manufacturer KBT for its crimpers says that it guarantees crimping of lugs in 30,000 cycles without loss of crimping quality.

Also ctf pliers have:

• unlocking mechanism from any position

• handle lock button

By the way, the handles here are no longer elongated and it’s no longer possible to comfortably grab them with both hands.

Why do you need to fix the handles? Imagine that you are standing on a stepladder and, under the ceiling, are crimping the handpiece sleeve in the junction box with one hand. You need to put it on the wire, put it in the right slot of the matrix and fix it before finally pressing it.

It will be problematic to do this in one go due to the uncomfortable position and cramped working conditions. Here, just the same, the fixing mechanism is indispensable. They inserted the sleeve, tightened it, intercepted it and squeezed it properly.

It is not recommended to crimp solid wires with CTB and CTF press pliers. To do this, you need to apply more effort and the ratchet mechanism must be designed for this. In this case, it is better to use other brands of tools from KBT. For example, a crimper - PK-16u and PK-35u.

In general, both sets of CTB and CTF can complement each other and be indispensable assistants when crimping sleeve insulated, non-insulated and other types of thin-walled sleeves and tips.

Of course, it is quite enough for the master of the station wagon to have one of them. However, remember that versatility doesn't always pay off. It is much more reliable to have a set of exactly tongs, and not a set of matrices for one press tongs.

Sets of press tongs CTF and CTB in online stores can be purchased within 5000 rubles.
The pliers themselves with only one matrix will cost at least two times cheaper. Choose for yourself required option can .

Various household and not only appliances require connection to the electrical wiring available in the building. And often for this you have to carry out special preparation of wires. To make this task easier, experts often use such a handy tool as crimping pliers. Not all home craftsmen are aware of this, so it will be useful for them to find out what this type of press is, what types it is, and how to handle it during repair and installation work.

general information

As man created new types of technology, new types of cable connections for various purposes, power and conductivity appeared. In order to connect the equipment in accordance with the current requirements and regulations, it is necessary to prepare the contacts of the leading conductors in a special way. To do this, you need to properly crimp their tips.. This is exactly what special crimping pliers were created for.

This is one of the indispensable tools that many radio amateurs, auto mechanics and electricians must have in their arsenal. With the help of such pliers, it is possible to crimp the contacts not only of ordinary cables, but also of specific connectors for non-standard connectors. Despite the fact that in recent years the range of tools for conducting electrical works has significantly expanded, pliers for crimping tips are still one of the most popular tools for performing such an operation. This is largely facilitated by the low cost of their production, availability and high efficiency.

Such ticks have quite simple design, thanks to which it is possible, even without special electrical knowledge, to crimp the tips. Such a press is a very reliable device with which you can crimp cables quite well. This guarantees a strong connection between all the conductor mi and directly connecting structure.

To date, there are enough a large number of models crimping tool, which may differ not only in functionality, but also in cost. The latter may depend on several factors:

• press manufacturer;
• construction type;
• quality and material of the final product.

Tip Description

Most cable lugs are marked with four letters - NShVI. In the deciphered version, this abbreviation will sound like "insulated pin sleeve tip." To put it in a more understandable language, this is a common sleeve for a flexible stranded wire. Its main purpose- protection of the end of the cable, which is used for fastening in a screw clamp terminal. After removing the insulation, a lug is put on the end of the cable, and then it is crimped with a special device. Most often, press pliers are used for this.

The metal part of the tip is most often made of electrolytic copper. It has insulation only on the back side. The thickness of the insulator is noticeable larger diameter metal part of the tip. It looks like a cuff. The tip is attached to insulating coating wires. Crimped it metal part , which fixes inside the cable core. When creating a connection between the handpiece and the screw clamp, the entire metal part is hidden in the socket of the device. Only the safe dielectric part of the cable is visible from the outside.

Tool types

If you go to any store that sells electrical products, you can be amazed great variety the crimping pliers offered there. Such a wide range due, among other things, to the fact that each manufacturer uses its own standard in the manufacture. This explains why such tools can have different functionality.

For example, in stores you can find highly specialized pliers designed for crimping wires only a certain kind, and a tool for a wider purpose, with which you can crimp cables when connecting and repairing not only household appliances, but also production equipment. Every consumer should know about this and take this moment into account when he goes to buy a press for crimping tips.

With the help of crimping pliers, you can create a high-quality and safe connection of an electrical and mechanical nature. It is this feature that is one of the main features of the classification of the instrument in question. It should be said what is the crimping pliers represent a class of pressing equipment. In most cases, they are used when working with low current systems to ensure reliable fixation of contacts.

Crimping pliers can be classified into several types depending on the purpose.

For stripping the sheath and insulation of the cable

With the help of this type of pliers, you can quickly and fairly accurately cut off a certain section of the insulation on the wire, while maintaining the integrity of the core itself. Modern crimping pliers often have the ability to adjust to a certain diameter so that you can easily remove the insulation from the core without risk of damaging it. This setting can be done in two ways:

• manually;
• automatically.

When trying to manually select suitable diameter there is a risk of error and damage to the wire. Therefore, it is best to make such a setting automatically. Then you can be sure that the removal of the braid will be done without negative consequences to cut the cord. It is this type of preparation for crimping that is used when working with distribution and junction boxes. Special attention must be drawn to the cutting edge, which must be sharp. Then the outer insulation will be removed in one step without the risk of "chewing" the wire into the tool.

For end sleeve press

For this type of operation, several types of hydraulic presses are offered for sale, which may differ in the shape of their sockets and the shape of the tool. There are models in which the sockets are made with plastic flanges, but some can be made without them. They can have a trapezoidal shape or be designed for crimping square-shaped cores.

Pliers whose sockets are equipped with plastic flanges should be selected when stranded wire lugs are to be crimped. With this task, they will perfectly cope thanks to square shape, which can ensure reliable fixation of all cores. Pliers of this type are ideal for mounting, as well as centering cables of any type of section. If you need to perform a more accurate and reliable crimping of contacts, it is necessary to choose pliers with an emphasis on the diameter of the cable.

For insulated cable lugs

If the wiring has insulated contacts, then a hydraulic crimping press should be selected. cable lugs oval shape. According to the standard, their matrix has three forms for the press, each of which corresponds to specific color: red, blue and yellow. And for each of these colors, there is a tip, sleeves and other connectors for sale that are designed to be used with it.

About to crimp insulated wiring using a terminal press of this type, care must be taken to ensure that the joint edge is correctly positioned. It should be strictly in the middle of the upper profile of the pincers. Compliance with this condition is great importance, since when placing the edge on the side, the reliability and tightness of fixing the electric core will suffer.

Such pliers are designed to work with a cable without insulation, as well as open-type conductors made of brass. In the design of such a tool, a special rod is provided. Crimping is carried out strictly in the center, while the rod must be planted directly on the separation seam. A slightly different design has pliers for crimping open lugs made of brass.

They have two types of clamps, among which one is for wire, and the second is for insulation. To perform the most reliable crimping of open contacts, it is recommended to attach a locator to them . This is a very handy device., with which you can ensure the exact position of the contacts. If the task is to crimp the terminals, then it is best to do this with special tongs for pressing plugs.

Principle of use

Understanding the principle of operation of pliers for crimping insulated lugs in wiring is not so difficult. To do this, it is enough to know the nuances of the workflow itself, during which it may be necessary to use them. In addition to the wire whose contacts need to be crimped, you will need a crimping tool and a connecting element that is attached to the end of the contacts.

During the installation and repair of various home appliances often have to work with wires. And for their quality performance, often reliable and secure connections are required. solve this problem without specialized tool impossible. Most often, crimping pliers are used for this. Today, such a tool is on sale in a wide range, thanks to which you can choose the most suitable option, taking into account the task facing the specialist.

However, the choice of pliers for crimping cable lugs is not simple task as it might seem at first. Even though in stores you can find universal pliers to perform such work, it is still recommended to choose a highly specialized tool that can guarantee the highest quality crimping of contacts. Accordingly, the crimping of the tips itself must be performed by a specialist, since for the quality of such work, it is necessary to have experience and knowledge.

• • Of course, for the entire instrument (with the exception of some Supplies) a guarantee is provided for a period of 1 to 5 years, specifically for hydraulic presses - 3 years.
• • At standard work It is recommended to change the oil at least once every two years. If the tool is used frequently, the oil should be changed more frequently. It is not difficult to determine the frequency of oil changes - if the press starts pumping too slowly, or jerkily, then it's time to check and top up or change the oil. When buying a hydraulic tool, you can immediately purchase KBT Hydraulic Oil for subsequent maintenance.
• • The resource of the tool is a loose concept. It depends on the intensity of use of the press - you crimp two tips a day, two hundred or two thousand. From the size of the tips - if you crimp only the tips with a section of 25 mm², then the tool will last much longer than if you crimp the tips with a section of 150 mm². And so on.
    According to world standards, the service life of hydraulic tools is about 5,000 crimps, for pressing tongs - up to 10,000. The actual resource of the KBT tool reaches 10,000 and 30,000 pressings, respectively. But that's not the point. The main thing is that when correct use tool and its timely maintenance (replacement of sealing rings, topping up and oil change), the KBT tool is guaranteed from three to five years (depending on the type of product), which best characterizes its resource.
• • Yes, they fit. In the models PGR-300 "KVT", PGRs-300 "KVT", PGRs-300A "KVT", PGRs-300AM "KVT", PGP-300 "KVT" and PGP-300A "KVT" matrices are the same. Also, sets of high-precision matrices of the NM-300 "KBT" series are suitable for all these tools.
• • Matrices in these tools are made according to a certain “average standard”, which allows for crimping of aluminum and copper tips and sleeves made both according to Russian GOSTs and DIN standards. The quality of crimping with such dies meets all the requirements, and has been verified by many years of tool sales. But if you need to crimp the tip and get a guaranteed professional result, then we recommend using specialized high-precision dies of the HM-300 KBT series, designed for crimping certain series of tips.
• • It all depends on the type of quick couplings used. If they match each other, then it is possible. Couplings used on the tool trademark"KBT" have the following characteristics: M22 thread with a pitch of 1.25. If your pump or press has the same thread, then they can be used with KBT equipment.
• • Can. But for this, it is necessary to remove the fixed handle from the hydraulic presses, drain the oil, remove the rubber container, and only after that adjust the valve. It is not necessary to drain the oil from the pumps, but you will have to partially disassemble the case. Plus, the valve must be set correctly, which is quite difficult without practice. Based on this, it is better to leave the valve setting to the service center specialists.
• • Each tool has its own advantages and depends on the frequency and conditions of its use.
    For example, a mechanical tool can be used at any temperature (including negative temperatures), hydraulic tools can only be used at temperatures from -15 to +50 ° C (the KBT tool uses frost-resistant oil). The mechanical tool requires minimal maintenance, and the risk of breakage is extremely low. With some mechanical tools, you can crimp the tip faster - just press the handles together once.
    It is more profitable to use a hydraulic tool if it is used frequently - working with hydraulics is much easier physically. Most KBT hydraulic presses are equipped with a two-speed pump stroke mechanism, which significantly saves time during crimping. The automatic pressure release valve in the PGRs models protects the tool from damage.
    In a word, the choice between hydraulics and mechanics can only be made by a person, knowing the conditions tool operation.
• • Any work should be carried out on a disconnected line. If absolutely necessary, you can use a special tool that is designed for work under voltage and marked accordingly. As of today, there is no such tool in the KBT product line.
• • The decision to buy a mechanical or hydraulic tool can be made by a person who knows in what conditions this tool will be used. AT this case, all-weather and all-weather power tool, requires minimal maintenance, is virtually indestructible and works faster (when equipped physical strength) than hydraulics.
• • These are specially designed high-precision dies for crimping very specific series or standards of ferrules. 99% of the dies in an inexpensive tool are made according to some “average standard”, and they can be used to crimp different tips, but the crimping quality will still not reach the professional level. Until now, specialized matrices at a price of about 80 euros per pair (one standard size) were available only from large European manufacturers. Now they are also in our assortment. Matrices fit the most popular models hydraulic tools - presses PGR-300, PGRs-300, PGRs-300A, PGRs-300AM, PGP-300 and PGP-300A. If you clearly know which tips or sleeves you will use, and the guaranteed quality of the work performed is important to you, then the HM-300 "KBT" series matrices are your choice!
• • Such dies are used for crimping various tension, connecting and contact fittings and are made to order. There are four types of dies for each tool: round die "A" for crimping aluminum clamps (an example of designation A-24/PG-60 tons, A-54/PG-100 tons); round die "C" for crimping steel clamps (designation example S-17/PG-60 tons, S-44/PG-100 tons) hexagonal die "MSh-A" for crimping aluminum clamps (designation example MSH-13.8- A / PG-60 tons, MSH-60-A / PG-100 tons); hexagonal die "MSh-S" for crimping steel clamps (example of designation MSh-32-S/PG-60 tons, MSH-48-S/PG-100 tons); To order matrices, you must specify them inner size(depending on the fittings being pressed) and to which press it is needed. Matrix production time is about two weeks.
• • The main difference between the KBT tool is that the assembly and quality control is completely carried out at the KBT Kaluga plant. Particularly critical parts are also produced at the factory, other components are obtained from third-party enterprises. The similarity with the tool of other manufacturers or sellers ends appearance, and then, if you do not look closely. Most of the parts that make up the tool differ from similar parts in tools from other manufacturers, which has been repeatedly verified when we were contacted with requests for the repair of third-party tools. We make every effort to ensure that the tool comes out reliable and of high quality. Work is constantly underway to modernize and improve existing models. Warranty repairs and post-warranty service are carried out on the KBT tool.

The key to any quality electrical connection is the area of ​​\u200b\u200bcontact of the wires - the larger it is, the more reliable the contact. Of course, all this is selected relative to the cross section of the connected wires, so the main thing here is to do without fanaticism. If the first connections of this type were long twists, crimped with pliers, now they are straight wires that crimp pliers fasten together inside a special crimping sleeve. The disadvantage of this connection method is the need to have a crimping tool and consumables in the form of bushings or lugs, but this is fully offset by an increase in the speed of work and an improvement in its quality.

Where are crimping pliers used?

Regardless of the size of the crimper, it has only two main uses - the preparation of current-carrying conductors for fixing them to the terminals of sockets, switches and other electrical appliances, as well as the connection of several wires to each other.

In the first case, crimping is justified if stranded wires are used. If they are clamped into the contact terminals without preparation, then over time, under the action electric current(it creates a microvibration) the veins will “shrink”, free space will appear between them and the contact will generally weaken.

This is one of the reasons why it is advised to use solid wires for laying power wiring, but with the spread of crimping devices for wire lugs, this recommendation has lost its meaning.

Crimping is also used when working with large-section cables - it was used even long before the advent of "household" devices. True, a high-quality connection can only be obtained using a special press for crimping cable lugs, which even now is far from being pocket-sized. To create the necessary force, such devices use the principle of a jack or a separate hydraulic drive - human force, even applied through a conventional lever, is not enough to compress a thick cable with high quality. An example of such a device in the video:

It will be useful to crimp and, if necessary, connect two or more wires. In this case, they are assembled together, a sleeve is put on them and crimped. In this case, the wires can be inserted into the sleeve both from one side and from both sides: in the first case, a kind of twist is obtained, and in the second - a coupling.

The advantage of this type of fastening is that after crimping, air does not penetrate into the sleeve - in fact, a tight connection is obtained. This allows you to connect in this way even copper and aluminum wires, the contact between which, under normal conditions, oxidizes over time.

Varieties of crimping pliers

Structurally, crimping pliers are divided into two main types - operating on the principle of pliers or diaphragm.

The first of them are more common - they perform squeezing only from two sides, but unlike pasatages, they have cutouts in the jaws. special form that act as guides. This allows you to perform high-quality fastening on the wire core of the lugs, the base of which in the cross section has a "P"-shaped shape.

In the video, various types of wire crimping tool:

The advantage of such devices that crimp wire cores is their relative versatility - they can “get close” to the tips from any side. The main drawback lies in the need to have several such pliers “on hand”, since cutouts for 3-4 cartridge sizes are usually placed on the jaws. As an option, you can purchase a universal crimping crimper with interchangeable dies, which are mounted on a special cassette. If you need to work with other types of tips, the old ones snap into place in the cassette and suitable ones are selected in their place.

Diaphragm devices can crimp sleeves from four or six sides - depending on the diaphragm mechanism. Due to the full girth of them, a better and tighter crimping of the end of the cable is performed, and the device automatically adjusts to any thickness of the sleeve.

Before choosing such a tool, one must take into account its main drawback - you can only crimp a sleeve into which the wires are inserted on one side - otherwise the pliers will remain on the wire, since their head is closed.

A few separate categories are crimpers that crimp computer cable type "twisted pair" and the like. The principle of operation of such a tool is the same as that of two-jaw pliers, but instead of iron or copper bushings, their matrices are "sharpened" to work with plugs for computers or telephones. Here, it is not crimping as such, but the displacement of contacts that cut through the insulation of the wires and tightly pressed against their cores.

How to work with crimping pliers - important nuances

The process of crimping wires is intuitive - the sleeve or tip is put on the wire(s), a matrix of tongs is supplied to it, the tool handles are closed and the contact is ready. In practice, most often the “first pancake”, or even several, turn out to be “lumpy”, and practically in literally– Connections may be far from ideal. There have also been cases when, in a seemingly well-compressed wire, contact deteriorated over time.

If the shape of the terminals is not maintained

In the first case, the squeezing force settings of the matrix parts are to blame, which can be different for both individual wires and the tips themselves. Because of this, professionals prefer to have at least two tools to avoid having to reconfigure the spring to work with different wires or sleeves.

The quality of work is also affected by the material from which the sleeves are made and their thickness. Tight terminals are always much easier to crimp and hold their shape better than those made of soft materials.

The correct orientation of tips with a “P”-shaped section is, although lying on the surface, but often ignored requirement, and after all, the misalignment of parts in any mechanism does not always fall into the zone of permissible error.

Twisting stranded conductors before crimping

For every experienced electrician who started with twisting and soldering wires, this movement is most likely already a reflex, but when crimping is performed for stranded lugs, then you have to get rid of it. The validity of this assertion can be verified simple experience- take a pair of single-core single-wire wires, place them crosswise and squeeze with pliers. In some cases, both wires are deformed, and sometimes only one, but at the same time it will be almost completely broken and will hang out on a thin isthmus. Of course, the conductivity of this vein will decrease significantly.

If the wires do not twist, then when the tip is crimped, they will be parallel to each other and, when deformed, they will simply fill all the voids without crushing each other.

The nuances of wire sleeves on the video:

Color marking of sleeves and matrices

Different sizes of sleeves some manufacturers mark individual flowers and the same labels are applied to matrices of ticks.

It must be remembered that unified system it has not yet been developed for this, so if you purchase sleeves focusing only on color, you can get consumables that are not quite suitable.

As a result - what to choose

Crimping pliers are very subject to the rule that each job needs its own tool, only here everything is a little more complicated, since a separate device is by and large needed for each type of wire used, if you do not want to mess with adjusting the spring force. Therefore, what specific tool is needed and in what quantity can only be decided on the basis of everyday work tasks.