Manual press pliers for crimping tips. Tools for crimping cable lugs. Color coding of tips

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

Features of crimping pliers

The operating principle of the tool is similar to the operation of pliers. The difference between crimping pliers for ferrules is complex profile 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 make switching connections between power units. The crimping process for cable lugs is quite simple. A sleeve is placed on the bare end of the wire or stranded wire. She is led into the opening of the ticks. Using the force of the fingers, the hands squeeze the levers of the tool, and the crimper compresses the sleeve with the wire.

Main types of ticks

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.

Passatizhny

The tip is crimped in the same way as pliers grip a part. Work surface The matrix has cutouts into which the tip shank is threaded. This design is suitable for those fastenings that do not require special reliability.

To increase crimping force, hydraulic ferrule crimping tools were invented. Thanks to this improvement, the pliers became more efficient. The design uses cylinders with pistons filled with oil, which creates a large pressure of the matrices on the tip sleeve.

Important! Some crimpers are equipped with several types of removable matrices. The versatility of the tool eliminates the need for pliers for each conductor cross-sectional size.

The originality of the design of diaphragm crimpers 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 pliers into the connection of the two ends of the wires.

Pay attention! The diaphragm tool is used as a press for pin or flat metal tips. The all-round clamp is much more effective than the plier type for covering the end switches of wire products.

Scope of application

Pliers for crimping wire lugs of certain designs are used depending on the cross-sectional composition of the cable product. 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;
• lugs and electrical cable large section;
• sequential crimping of wires;
• swage computer cables.

Stranded wires and thin-walled ferrules

Thin-walled lugs are used for small-section wires - from 0.5 to 3.5 mm2. The elements are marked NSHVI. The abbreviation stands for as follows:

• N – tip;
• Ш – pin;
• B – bushing;
• And - isolated.

NSHVI lugs are used for crimping stranded copper wires with subsequent insertion into sockets of various electronic devices. The crimper handles are compressed until the spring mechanism of the device is activated.

Pay attention! Multi-stage clamp matrices 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 hand crimping tools.

Press pliers create a strong and reliable compression of the tips. Without them, one would have to twist stranded cores or solder the terminals of switchgear devices. The use of pressed end switches completely eliminates problems associated with breakage of thin wires, wire breakage, and the risk of short circuit.

Stranded wires and thick-walled ferrules

Thick-walled shanks are used for crimping multi-core power cables. Their maximum cross-section reaches 16 mm2. Press pliers PK-16 are used only for multi-core wires. The tool can compress the sleeve so tightly that it can easily break a single core.

The cable crimping process occurs in several stages:

1. At the end of the wire, mark the length of the sleeve.
2. Using special nippers, remove the insulation from the marked area.
3. Place a piece of heat-shrinkable tubing so that it does not touch the exposed wire.
4. The cleaned end of the cable is inserted into the sleeve. The insertion of the wire should be tight, but without force.
5. The tip is crimped using pliers.
6. The protruding veins are bitten off.
7. Use a hair dryer to heat the heat shrink tube until it tightly grips the cable.

If the letter “U” is indicated in the marking of the tool, this means that the ratchet mechanism is located inside the handles, which creates a large force on the jaws of the crimper. The PK-16-U pliers compress more easily during cable crimping.

Large cross-section lugs and electrical cable

Crimping for ferrules electric cable large cross-sections are produced using a manual hydraulic press. Initially, the valve of the device is slightly open, and the rod slowly moves to its original position. At the beginning of the piston stroke, the valve opens completely, which ensures compression of the dies with great force.

Large cross-section cables are rarely found in indoor equipment. Hydraulic pliers are mainly used for installing lugs on high-voltage cables for fastening them in switchboards of industrial facilities. Hydraulic crimping pliers for dimensional tips are also used when laying and switching power cables in energy panels of entrances residential buildings, administrative buildings and civil buildings.

The hydraulic press is equipped with cassettes with replaceable 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 electrical safety of the device. Crimping of two cables with a double-sided sleeve is carried out during transfer electrical panel. These pliers for simultaneous crimping of two wires are also used when extending copper conductors with a diameter of 6-12 mm2.

Consistent wire crimping

This method is used when connecting sections of wires into a single whole. This is especially important for serial compression conductors with cores made of different metals. For example, when you need to make a connection between aluminum and copper wires, use a crimp sleeve.

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

The bare wires are inserted into the sleeve on both sides. After this, the sleeve is compressed with pliers. The compressed sleeve prevents air from entering the connection, which prevents the occurrence of oxidation processes in the metal of the wires.

Computer cable crimping

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

Plastic RJ-45 connectors are used as tips. Polymer tips are intended for insertion into the sockets of hubs and network adapters. A twisted pair consists of eight wires. Insulated conductors twisted in pairs minimize interference when electric currents pass through them.

Special crimpers are used to crimp cable ends. The RJ-45 connector is a plastic box with an opening 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 unraveled and aligned in a certain order;
• Using wire cutters, cut the wires evenly so that the bare ends of the cores are formed;
• the wires are inserted into the RJ-45 connector, the cut wires with their cores should be tightly adjacent to the back of the terminals;
• The plastic connector is inserted into the opening of the pliers, then the tool handles are squeezed.

The twisted pair wires should be arranged from left to right in the following order (looked from above from the entrance to the connector):

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

How to use crimping pliers correctly

Self-mastery of crimping pliers may initially be accompanied by the creation of a poor-quality connection between the sleeve or tip and the wire. It often happens that what appears to be a reliably performed crimp hides a bad contact. This can happen for two reasons.

If the shape of the terminals is not maintained

A discrepancy between the size of the tip or sleeve and the opening between the matrix jaws can cause distortion of the compressed element. Before you start crimping, you should try on the tip to the opening in the pliers. 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 fit into the connecting element with light tension. If you have any doubts about the reliability of the fastening, you should practice on separate sections of the cable. After crimping by hand, you need to check the strength of the connection. If there is the slightest play, the crimp should be rejected and crimping should be resumed with a different end cap.

Excessive clamping may damage the conductors inside the sleeve. The accompanying documentation for crimping pliers usually indicates the cross-sectional dimensions of the tips directly for each opening of the pliers. The use of connectors made of soft metal alloys should be avoided. Over time, the tip may lose strength and contact will become unreliable.

Twisting stranded wires before crimping

A mistake can be made due to the habit of twisting the wires, which is done before insulating or soldering manual connections. This is absolutely impossible to do.

You can check the harmfulness of twisting in a simple way. It is worth squeezing the twisted multi-core cables with pliers to make sure that there is deformation and damage to the integrity of the wiring.

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

Color coding of tips

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

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

Color marking table for NShVI tips

Crimping wires using pliers cannot compare with hand twisting or soldering in terms of quality and speed of connections. For any connections you can always choose the right crimper model.

Video

Various household and other appliances require connection to the existing electrical wiring in the building. And often for this it is necessary to carry out special preparation of the wires. To make it easier to cope with this task, specialists often use this handy tool, like pliers for crimping tips. Not all home craftsmen are aware of this, so it will be useful for them to know what this type of press is, what types it comes in 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 equipment in accordance with current requirements and standards, it is necessary to prepare the contacts of the leading wires in a special way. To do this, you need to properly crimp their tips.. This is precisely why special crimping pliers were created.

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, you can perform crimping of contacts not only on ordinary cables, but also on specific connectors for non-standard connectors. Despite the fact that recent years The range of tools for electrical work has expanded significantly; pliers for crimping terminals still remain one of the most popular tools for performing such an operation. This is greatly facilitated by the low cost of their production, availability and high efficiency.

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

Today there are enough on sale large number models of crimping tools, which may differ not only in functionality, but also in cost. The latter may depend on several factors:

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

Description of the tip

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 more understandable terms, this is a regular bushing 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 ferrule is put on the end of the cable, and then it is crimped with a special device. Most often, press jaws 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 over insulating coating wires. It is crimped metal part , which fixes the cable core inside. When creating a connection between the tip and the screw clamp, the entire metal part is hidden in the device socket. Only the safe dielectric part of the cable is visible from the outside.

Tool Types

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

For example, in stores you can find highly specialized pliers designed for crimping wires only certain type, 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 point into account when he goes to purchase a press for crimping tips.

Using crimping pliers, you can create a high-quality and safe electrical and mechanical connection. It is this feature that is one of the main characteristics of the classification of the instrument in question. It should be said What are 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 their purpose.

For removing cable sheath and insulation

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

• manually;
• automatically.

When trying to manually select suitable diameter There remains a risk of error and damage to the wire. Therefore, it is best to make such adjustments automatically. Then you can be sure that the braid will be removed without negative consequences for cutting the cord. It is this type of preparation for crimping that is used when working with distribution and branch boxes. Special attention It is necessary to pay attention to the cutting edge, which must be sharp. Then the outer insulation will be removed in one action 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 design 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 chosen when it is necessary to crimp the ends of a stranded wire. They will cope with this task perfectly thanks to square shape, which can ensure reliable fixation of all cores. This type of pliers is ideal for installation and centering of cables of any type of cross-section. If you need to perform more accurate and reliable crimping of contacts, you need to choose pliers with an emphasis on the cable diameter.

For insulated cable lugs

If the wiring has insulated contacts, then you should choose a hydraulic press for crimping cable lugs oval shape. According to the standard, their matrix has three forms for the press, each of which corresponds specific color: red, blue and yellow. And each of these colors has its own tip, sleeves and other connectors for use with it.

About to do the crimping insulated wiring using a lug press of this type, care must be taken to ensure that the joint edge is positioned correctly. It should be located strictly in the middle of the upper profile of the pliers. Compliance with this condition has great value, since when placing the edge on the side, the reliability and tightness of the fixation of the electrical core will suffer.

These pliers are designed to work with cables without insulation, as well as open conductors made of brass. The design of such a tool includes a special rod. The crimping is done strictly in the center, and the rod must be seated directly on the dividing seam. The pliers for crimping open tips made of brass have a slightly different design.

They have two types of clamps, among which one is designed 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 convenient device, with which you can ensure the exact position of the contacts. If the task is to crimp terminals, then it is best to do this with special pliers for pressing plugs.

Principle of use

Understand how crimping pliers work insulated tips Wiring is not that difficult. To do this, it is enough to know the nuances of the work process itself, during which the need to use them may arise. 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 installation and repair of various household devices, it is often necessary to work with wires. And for their high-quality implementation, it is often requires the creation of reliable and secure connections. Solve a similar problem without specialized tool impossible. Most often, crimping pliers are used for this purpose. Today, such tools are available for sale in a wide range, thanks to which you can choose the most suitable one. suitable option taking into account the task facing the specialist.

However, the choice of pliers for crimping cable lugs is not the same. simple task, as it may seem at first. Even though you can find universal pliers in stores for performing 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 carried out by a specialist, since in order to carry out such work efficiently, it is necessary to have experience and knowledge.

Content:

For high-quality connection of contacts of devices and equipment, crimping of cable ends and wires that are connected to them is used in electrical engineering - this method provides an excellent connection of conductive surfaces. In order to use crimping, you need tips or sleeves that have different type and purpose. The crimping method requires a special tool. Let's look at what types of tips there are and how they are crimped.

Types of lugs for crimping

For every average person, a striking example of incorrect connection of wires is the staircase switchboard; many apartment owners have melted wires in the panel and have twists. Crimping lugs for wires can save citizens from the possibility of heating and fire electrical wiring as a result of poor-quality contact of wires, lack of cable lugs.

When there is good contact between the connected cable or wire and the connecting device, the transition resistance is minimized, and with an increase in the current load on the contact group, they can heat up in the event of poor contact. Sleeves and tips are intended to remove or minimize contact resistance, in other words, to eliminate poor-quality contact under a bolt or screw.

To carry out crimping (crimping for lugs) of wires and cables, special products are used - lugs and sleeves. Tips can be for stranded wires or single-core wires; they are divided according to their purpose and the type of wire for which they are used (copper or aluminum).

For crimping copper cable cores, lugs made from seamless copper tube, which is flattened on one side and has a hole for a screw connection. This type of tips is:

• With different diameters for a wire and a mounting hole that does not have protective coating;
• for crimping, electrolytic tinned with different holes for fastenings.

The markings for this type of tips are as follows:

• without coating, TM – X – Y, where X is the wire cross-section, Y is the size of the mounting hole;
• coated, TML – X – U.

There is also a type of lugs with an inspection window; these are tinned copper products for terminating cable cores and wires. A special feature of this type is the ability of the termination performer to control the correctness of crimping through the control window. This type of product is marked as TML(o), it is noteworthy that they can be installed on the ends of cables using solder and soldering, which almost completely removes the value contact resistance.

Quite often in electrical engineering there is a connection between an aluminum wire and a copper cable; in this case, it is recommended to use aluminum-copper lugs for a high-quality connection of the aluminum wire and the copper busbar of the panel.

With decreasing overall dimensions instruments and devices, pin products have become popular tips for terminating. They are used in electrical equipment and circuit breakers in protection devices. With the reduction of clamping fasteners, the pin is the most optimal solution for good contact. This species is labeled as NSP.

NShVI tips

Cable lugs for crimping NSHVI are a pin-sleeve product with insulation. Electrolytic copper is the material from which it is made; insulation is installed on the back side, which is thicker than the metal part. When the terminated wire with this tip is inserted into the socket, only the insulated part of it remains under the clamp on the outside. In industry and in everyday life, this type of lugs is used for cables with a cross-section of up to 35 sq. mm; they are crimped with a special tool.

There are several modifications of this tip, which differ in the number of connected wires in one tip. For two cables, the marking looks like NSHVI2, there are no structural differences in this tip, the same metal part and PVC cuff, but the diameter of the sleeve (skirt) is larger, designed for two wires.

Features of working with NSHVI

Cable lugs of this type are intended only for multi-core cables; they cannot be used in the termination of wires with a single core. For rigid (single-core) wires, crimping with bushings (sleeves) without insulation is used. Crimping of a stranded wire is carried out as follows:

• the cross-section of the wire is selected, the brand of the tip is selected, into which the conductors must fit freely and tightly from the side of the skirt;
• in practice, the type of tip is selected with some margin. Example: a PV-3 wire with a cross-section of 1.25 sq. mm can be terminated with a tip of 1.5 sq. mm. The section of the skirt is up to 2.5 sq. mm.

Tool

Crimping of cable lugs is carried out with a special tool that is designed and manufactured for these purposes. To crimp the lugs, a tool is necessary, since a person with simple force cannot create the necessary force for high-quality termination of the cable core. Which tool to choose for crimping depends on what cross-section of wire or cable you are working with. Let's list the most used tool:

1. Press jaws of the PK2 or PK2M brand are hand tool, which is used in terminating wires and cables with a cross-section of up to 10 sq. mm.
2. Press jaws of the PK1 or PK1M brand are a reinforced version hand pliers with long handles, they can be used to terminate conductors up to 50 sq. mm.
3. Hydraulic hand pliers can be used to terminate conductors up to 10 sq. mm without much effort.
4. Hand press, which is used in industrial production for wire with a cross-section of up to 240 sq. mm.
5. Hydraulic press with electric drive or foot pedal, terminates cables up to 300 sq. mm.

Sleeves for crimping

Not every device or instrument uses a cable lug for switching an external circuit; there is also a sleeve termination; its selection is made according to the type of wire being connected (copper, aluminum). For cables with copper conductors - marking of sleeves GML, where:

• G - name of the product, sleeve;
• M - the material from which it is made, copper;
• L - the product has a tin-plated coating.

For aluminum wires GAO brand is selected: aluminum sleeve closed type. When it is necessary to make a connection with the transition of aluminum to copper, a product made of an alloy is selected. The use of products for copper wires on aluminum conductors, this is a heat couple that will heat up due to the electrochemical reaction taking place in the material of these conductors when connected.

Preparation for crimping

You can’t just put a cable lug on a core; you need to perform a number of preparatory steps:

• clean the desired length of the end of the wire or cable from insulation - you can apply special tool, stripper;
• twist the wires by hand and insert them from the side of the skirt into the tip;
• We first select the tip according to the cross-section of the core, observing the conditions for free and tight fit of the tip into the sleeve.

Crimping of wires with lugs is performed with a special tool. Each press has a marking of the dies and the main part according to the type of tip or core cross-section. Now the color standard is observed, for this reason it is easy to align the section and matrix in the desired position.

How to crimp a wire

If you have not crimped cable cores before, you need to practice on unnecessary scraps of wire or cable. To obtain a high-quality connection, you must adhere to the established rules:

1. The cable inserted into the sleeve (sleeve with flaring) of the tip must be held by hand in the socket.
2. After making sure that the matrix corresponds to the selected tip, you can begin to squeeze the handles of the press until the ratchet mechanism is activated and there is an audible click.
3. The ratcheting device of the press simplifies the compression process. The mechanism does not allow the press to open, and when the wire is crimped unsuccessfully, it must be unblocked.
4. Double-circuit crimping compresses the insulated part of the tip and the metal contact. In such a matrix there are two sockets, they are different in size, so you need to carefully check that the cuff fits into its socket, and the metal contact of the tip fits into its own.

Conclusion

Each lug must have a corresponding wire, the most common mistake When crimping cable cores, the problem is that the selected tip and the material of the wire do not match; you should not put a bushing that is too loose on the wire. Do not use the products large diameter for terminating conductors with a smaller cross-section, this can lead to an increase in contact resistance and heating of the contact. You cannot cut the sleeve into two parts in order to save products; do not use homemade tips.

For high-quality crimping of cable cores, you need to use a special tool; a chisel and hammer will not be able to make the necessary compression and provide high-quality contact.

Modern electrical engineering is constantly being improved, including in the field of connecting wires and cables for various purposes, power and conductivity. The quality of electrical wiring largely depends on how well the leading conductors and their contacts are prepared. They must be crimped in a certain way, and this task is completely solved by special pliers for crimping wire lugs. They are widely used among electricians. The tool is used to crimp not only conventional cables, but also various connectors used in non-standard connectors.

Using crimping pliers

All press jaws, regardless of their size, are designed to perform two main tasks. In the first case, several wires are securely fastened to each other, and in the second, current-carrying conductors are prepared for their subsequent fastening in the terminals of various electrical devices.

First of all, crimping is required when connecting multi-core wires. If they are inserted into the contact terminals unprepared, then gradually, under the influence of microvibrations created by electric current, the individual cores will become compacted. Free space is formed between them, and therefore the contact will become much weaker. For this reason, power wiring was previously always laid with single-core wires. However, after press pliers appeared, this recommendation lost its relevance.

Connecting large cross-section cables using the crimping method has been used since ancient times, when household tools It hasn't happened yet. The quality of such operations was ensured by the use of special powerful presses capable of creating the necessary force. These devices operate on the principle of a jack, and many of them have a separate hydraulic drive. With the help of such presses, even the thickest cables are reliably connected.

The crimping method has proven itself well when connecting two or more wires. For this purpose, crimping and wire pliers are used. A special sleeve is put on their ends, assembled together, and then crimped. Depending on the type of connection, the wires are inserted from one or both sides of the sleeve. The first option allows you to get reliable twisting, and the second - high-quality.

Main types and varieties of ticks

Structurally, all crimping pliers - crimpers can be of two types. The former work like, and the latter are diaphragm. The first option is the most widely used. In this case, compression is performed only on both sides. The main difference from pliers are the cutouts special form located in the sponges. They act as guides and ensure high-quality fastening of the lugs to the wire core.

Such crimping pliers are considered to be somewhat universal, since they can grip tips from all sides. The main disadvantage of such pliers is the presence on the jaws of only 3-4 cutouts for different sizes sleeves Therefore, during work you have to use several tools. Most the best option It is considered to be the use of a universal crimper, the kit of which includes replaceable dies mounted on a special cassette. In order to crimp the wire, the most suitable tip is selected, and the unnecessary one is inserted into the cassette in its place and fixed.

Diaphragm pliers can be used to perform four- or six-way compression, depending on the design of the working mechanism. Full coverage on all sides allows for the tightest possible crimping of the cable ends. During operation, the pliers are automatically adjusted to a specific sleeve diameter. The main disadvantage of such a tool is the possibility of crimping the sleeves on only one side due to the closed head.

A separate category includes crimpers designed for crimping computer cables. They work in the same way as pliers with two jaws, with the exception of the matrices themselves, which have a specific configuration for computer and telephone plugs. In this case, the essence of crimping is to displace the contacts that cut through the insulation of the wire and are pressed tightly against its cores.

Depending on the purpose, all crimping tools are divided into the following categories:

• Removing insulation and sheathing from wires and cables. With the help of these pliers, a section of insulation is cut off without damaging the cores. They can be configured to required diameter manually or automatically. It is imperative to ensure that the cutting edge is sharp so that the outer insulation is cut in one motion.
• Crimping of end sleeves. The tool for crimping tips has trapezoidal or square shaped sockets. They can be with or without flanges. To ensure reliable and accurate clamping of contacts, pliers must be selected according to color markings that correspond to a specific diameter.
• Crimping pliers for insulated ferrules. The tool has an oval shape, and the matrix contains three press sockets. They are marked in red, blue and yellow. These colors correspond to sleeves, tips and other types of connectors with similar color indications. This marking connects the insulated tips, placing them in the desired socket.
• Crimping of non-insulated terminals. The main working element is a special rod located along the dividing seam and pressing the sleeve in the center.

Crimping with a hydraulic tool

High-quality crimping significantly improves current conductivity at the joints, prevents overheating and emergency situations due to poor contact. At home, for these purposes, ordinary household pliers are used, designed to work with wires with a cross-section of up to 4 mm2.

For continuous or combined crimping of a cable with a cross-section of 4-400 mm2, it is necessary to use more powerful tools that provide high working pressure. Hydraulic tongs or hydraulic presses fall into this category.

The design uses cylinders of different diameters, interconnected and representing a system of communicating vessels. Each of them contains a piston. The internal cavity of the cylinders is filled with water, oil or other suitable liquid, therefore such a tool is hydraulic.

In accordance with Pascal's law, the force acting on any point of a liquid at rest is uniformly distributed throughout the entire volume. Thus, if a certain force is applied to a piston of a smaller diameter, then when transferred to a large piston, it will increase. The greater the difference between the areas of the pistons, the greater the force generated on the large piston.

Each hydraulic tool of this type has a single, double or triple action. Equipment simple action equipped with one working element - a movable partition. Double or triple action presses have two or three working bodies, respectively. Their work processes are coordinated with each other, and general management carried out using special distribution equipment.

Structurally, a hydraulic press can be vertical or horizontal, closed or open. With this tool you can crimp not only metal, but also other materials.

When choosing a hydraulic tool, it is necessary to take into account the presence of a pressure limiting valve. This element provides additional reliability, eliminating overload due to pressure. You should pay attention to the types of pressing heads, which are open or closed, as well as the diameters of the working sections. All hydraulic tools consist of subgroups, each of which performs operations with cables with cross-sections up to 70, 120, 300 and 400 mm2.

How to use crimping pliers correctly

Each pliers is used in accordance with its intended purpose. However, there are general principles that apply to any tool. Each operation requires a wire or cable of a certain cross-section, the pliers themselves, as well as sleeve tubes or other connecting elements.

For example, you can take Internet wires.

1. The ends of the wires are cleared of external insulation. This operation requires pliers with a semicircular notch at the bottom and a cutting edge at the top. The wire is placed in the recess, after which its upper side is pressed with a blade. 1-2 turns are made around the cable, the insulation becomes cut and is removed without any effort. For normal crimping, you will need a cleaned area 3-5 cm long.
2. The cable conductors are aligned and placed in required sequence by connector type. They are pressed closely together and cut so that 1-1.5 cm remains for connection.
3. The wires are inserted into the connecting device while maintaining the sequence. In this case, the lower recess of the connector must reach the cable insulation so as not to cause damage when crimping actions are performed.
4. The entire device fits into seat ticks. After re-checking the correct arrangement of the flowers, crimping is performed.
5. Upon completion, the integrity of the connector and the strength of the connection are checked.

• • Of course, for the entire instrument (with the exception of some consumables) a warranty 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 you use the tool frequently, the oil needs to be changed more often. The frequency of oil changes is not difficult to determine - if the press starts pumping too slowly, or jerkily, then it’s time to check and add or replace the oil. When purchasing a hydraulic tool, you can immediately purchase “KVT” hydraulic oil for subsequent maintenance.
• • The service life of a tool is a flexible concept. It depends on the intensity of use of the press - you compress two tips a day, two hundred or two thousand. From the size of the tips - if you crimp only tips with a cross-section of 25 mm², then the tool will last much longer than if you crimp tips with a cross-section of 150 mm². And so on.
    According to international standards, the service life of a hydraulic tool is about 5,000 crimps, and for press jaws – up to 10,000. The actual service life of the KVT tool reaches 10,000 and 30,000 crimp tests, respectively. But that's not the main thing. The main thing is that when correct use tool and its timely maintenance (replacing o-rings, topping up and changing oil), the KVT tool is provided with a warranty of three to five years (depending on the type of product), which best characterizes its service life.
• • Yes, they do. In models PGR-300 "KVT", PGRs-300 "KVT", PGRs-300A "KVT", PGRs-300AM "KVT", PGP-300 "KVT" and PGP-300A "KVT" the matrices are the same. Also, sets of high-precision matrices of the NM-300 “KVT” series are suitable for all these tools.
• • The matrices in these tools are made according to a certain “average standard”, which allows crimping of aluminum and copper tips and sleeves made both according to Russian GOST standards and to the DIN standard. The quality of crimping with such dies meets all requirements and has been verified by many years of tool sales. But if you need to crimp the tip and are guaranteed to get professional result, then we recommend using specialized high-precision dies of the NM-300 “KVT” series, designed for crimping certain series of tips.
• • It all depends on the type of quick-release connections used. If they match each other, then it is possible. Couplers used on the tool trademark“KVT” have the following characteristics: M22 thread with a pitch of 1.25. If your pump or press has the same thread, then it can be used with KVT equipment.
• • Can. But to do this, you need to remove the fixed handle from hydraulic presses, drain the oil, remove the rubber container, and only then adjust the valve. There is no need to drain the oil from the pumps, but you will have to partially disassemble the housing. Plus, the valve must be set correctly, which is quite difficult without practice. Based on this, it is better to leave the valve adjustment 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), while a hydraulic tool can only be used at temperatures from -15 to +50 °C (the KVT tool uses frost-resistant oil). Mechanical tools require 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 you use it frequently - it is much easier physically to work with hydraulics. Most KVT hydraulic presses are equipped with a two-speed pump mechanism, which significantly saves time during crimping. The automatic pressure relief valve in PGRs models protects the tool from damage.
    In short, the choice between hydraulics and mechanics can only be made by a person who knows the operating conditions of the tool.
• • Any work should be carried out on a disconnected line. If absolutely necessary, you can use a special tool designed to work under voltage and marked accordingly. Today, there is no such tool in the KVT product line.
• • The decision to purchase a mechanical or hydraulic tool can be made by a person who knows in what conditions the tool will be used. IN in this case, an all-weather and all-season mechanical tool, requires minimal maintenance, is practically not susceptible to breakdowns and works faster (if equipped). physical strength) than hydraulics.
• • These are specially designed high-precision dies for crimping completely specific series or standards of tips. 99% of dies in inexpensive tools are made according to some “average standard”, and they can be used for crimping different tips, but the quality of crimping will still not reach professional level. Until now, specialized matrices at a price of about 80 euros per pair (of one standard size) were only available from large European manufacturers. Now they are also in our assortment. The matrices come to 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 NM-300 “KVT” series matrices are your choice!
• • Such dies are used for crimping various tension, connecting and contact fittings and are manufactured to order. There are four types of dies for each tool: round die “A” for crimping aluminum clamps (example designation A-24/PG-60 tons, A-54/PG-100 tons); round die “S” for crimping steel clamps (example designation S-17/PG-60 tons, S-44/PG-100 tons) hexagonal die “MSh-A” for crimping aluminum clamps (example designation MSh-13.8- A/PG-60 tons, MSh-60-A/PG-100 tons); hexagonal matrix “MSh-S” for crimping steel clamps (example designation MSh-32-S/PG-60 tons, MSh-48-S/PG-100 tons); To order matrices, you must indicate them inner size(depending on the fittings being pressed) and what press it is needed for. The production time for matrices is about two weeks.
• • The main difference between the KVT tool is that assembly and quality control are carried out entirely at the Kaluga KVT plant. Particularly critical parts are also produced at the factory; other components are obtained from third-party companies. The similarity to tools from other manufacturers or sellers ends appearance, and even then, if you don’t look closely. Most of the parts from which the tool is assembled differ from similar parts of tools from other manufacturers, which has been repeatedly verified when we have been contacted with requests to repair third-party tools. We make every effort to ensure that the tool is reliable and of high quality. Work is constantly underway to modernize and improve existing models. The KVT tool provides warranty repairs and post-warranty service.