Crimping of terminals and tips. Crimpers for crimping insulated and non-insulated terminals and lugs. Stranded wires and thin-walled lugs

- 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 changing the oil - 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 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 be sure 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 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 crimped different tips, but the quality of crimping still will 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 are suitable for the most popular models of 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.

Crimping tools for lugs are devices that simplify the mechanical compression of connectors, wire contacts. With the help of presses, crimpers, crimping pliers, they install electrical connection online, troubleshoot. We offer devices for the following types of crimping:

hexagonal;

wedge-shaped;

trapezoidal.

Design and advantages of press machines

Crimping tools are made from hardened steel. They have a small weight, compact size, simple principle of operation. The devices consist of a ratchet mechanism, matrices, devices for unlocking and adjusting the crimp level, ergonomic handles. They are widely used in manufacturing repair centers, at home thanks to the functional features:

provide uniform crimping of cable cores and end sleeves;

create the maximum possible area of the contact association;

suitable for clamping insulated tips various sections, telecommunication connectors.

They differ in crimping methods: oval, square or four matrices. There are also universal devices with interchangeable nozzles.

Sale of crimping tools online at AVS-electro

You can buy crimping tools in our online store. The catalog contains models of mechanisms with removable matrices and fixed nozzles. Products manufactured by ABB, DKC, IEK, Legrand, Schneider Electric and other brands comply with international standards, safe to operate.

Hello, dear readers of the Electrician's Notes website.

In today's article, I will share with you information about the tool for crimping insulated ferrules - this manual press tongs EGI-60 made in Italy. They are also called "crimpers". At the end of the article I will show specific example how to work with them.

A bit of history. The Italian company EGI began its activity back in 1973 and to this day is engaged in the production and production of professional tool for electrical installation. To be honest, I have no doubts about the quality of this tool. Maybe someone will refute my thoughts.

Here is the packaging.

Appearance.

EGI-60 are designed for crimping insulated:

ring tips NKI
fork lugs NVI
pin round tips NShKI
flat and plug connectors RPI-P, RPI-M, RSHI-P, RSHI-M (mother and father)
piercing couplers OV
connecting sleeves GSI

The matrix (sponges) of the EGI-60 pliers allows you to crimp the cores with a cross section from 0.25 to 6 (sq. mm). These pliers are just right for domestic use, for example, for crimping flexible stranded conductors wires and cables for, RCDs, sockets, switches, chandeliers, lamps, electricity meters, etc.

For production purposes, we have a hydraulic press that can be used to crimp conductors of wires and cables with a cross section of 16 to 240 (sq. mm). I will talk about it in more detail in my next articles. Subscribe to the newsletter.

The device and parameters of the press tongs EGI-60

Pincers have the strengthened three-hinged lever mechanism.

The handles are made of high-quality plastic, and the body material is made of steel.

The length of the handles is 15 (cm), which allows crimping with two hands. Although it is not difficult to cope with one hand.

The handles are connected to the jaws using pins with retaining rings.

The EGI-60 has a ratchet mechanism that mechanically blocks the opening of the handles until the crimping cycle is completed.

Thus, the risk of “underpressure” due to human error is reduced.

If, suddenly, you have chosen a tip or core of an inappropriate section and have already begun crimping, then the ratchet mechanism can be unlocked at any time using the “dog”.

This model does not have a matrix pressure regulator.

The weight of these ticks is about 500-600 (g).

The pliers are equipped with a non-removable cast three-position matrix (or in simple terms"sponges").

There are three standard crimps in the die. Each crimp for clarity is painted in the appropriate color:

red - 0.25 - 1.5 (sq. mm)
blue - 1.5 - 2.5 (sq.mm)
yellow - 4 - 6 (sq.mm)

Manufacturers of insulated lugs, sleeves, connectors and taps specially produce them in accordance with these colors (insulating collars are painted), because it is very convenient for installation and speeds up the crimping process.

During crimping, each crimp puts a stamp on the body of the tip or sleeve with the following letter:

red - I (1)
blue - G (2)
yellow - E (6)

These letters are so small that I could hardly see them. And even the camera could not clearly focus on them. So do not judge strictly by the photo.

How to use press tongs when crimping insulated ferrules

Crimping is one of the most reliable ways contact connections. I spoke in detail about the advantages of this method in an article about - follow the link and read.

Now let's move on to an example.

Remember the most basic rules of crimping!!!

1. How to choose the brand of wire?

Crimping of insulated lugs and sleeves is possible ONLY on multi-wire (flexible) copper wires. For single-wire (rigid) wires, bare lugs must be used.

As an example, consider compression copper wire PV-3 1x2.5 sq. mm (the new designation for this wire is PuGV).

2. What type and section of the tip should I choose?

The tips are not designed for one specific wire section, but for several ranges at once. Agree, very convenient.

Thus, for the considered wire PV-3 1x2.5 sq. mm, I chose the ring lug NKI 2-6, designed for a wire cross section from 1.5 to 2.5 (sq. mm).

The tip could be chosen not only as an annular NKI, but fork - NVI or pin - NShKI. It all depends on the operating conditions and connection method.

3. Stripping

We remove the insulation from the wire core to a length equal to the tubular part of the tip. Recently, I have been using to remove insulation.

It is the tubular part that is the point of contact of the wire with the tip - it can also be called the contact part.

The tubular (contact) part of the tip can be determined visually. Its diameter is somewhat smaller than the diameter of the insulating cuff.

After removing the insulation, the core of the wire must be twisted a little to avoid the occurrence of bends and plexuses of its individual conductors.

4. We put the tip on the wire

The stripped wire should protrude beyond the insulating collar by no more than 1 (mm), and it is better to be flush with its edge.

The insulation of the PV-3 wire must go inside the insulating collar until it stops with the tubular part.

We select the appropriate crimp on the matrix (in my example it is blue) and start the wire with the tip like this.

Because crimping is double-circuit (I talked about this at the beginning of the article), then make sure that one circuit compresses the tubular (contact) part of the tip, and the second - the insulated cuff over the wire insulation.

6. Tip crimping

We hold the wire from falling out of the tip and begin to squeeze the handles of the tongs until the ratchet mechanism is unlocked.

Crimping occurs by pressing to a certain depth the copper tip of the NCI into the copper flexible stranded wire PV-3 along the selected crimping profile.

After pressing in without fail we check the mechanical strength of the resulting connection and the integrity of the insulating collar.

On the surface of the insulated cuff, an imprinted brand in the form of the letter "G" is visible.

Here's what happened.

And this is the view from the back.

P.S. Now you can imagine how to crimp insulated ferrules using EGI-60 pressing tongs and their analogues. Thank you for your attention.

Every house, apartment or garage has an electrical connection, where it often becomes necessary to repair old wiring or install new ones. When laying electrical wiring, it is required, and to do it reliably, this is the key to the correct operation of electrical appliances and safety. The best way to do this is with electrical cable crimps.

If the wires are loosely connected, for example, by twisting or soldering, the junction heats up, which most often leads to a fire. Such an unreliable connection does not provide proper throughput and causes instability electrical network, which leads to the failure of electrical equipment.

These shortcomings are deprived of the connection method using crimping (crimping) of wire lugs. To do this, use a special tool - crimpers (crimps), which provide tight and high-quality contact.

Strictly speaking, wire crimping is about the same as in other areas of activity.
Creating the tightest possible connection by applying mechanical force.
Creating (if possible) an inextricable connection that can withstand significant physical exercise to break.
The ability to ensure the continuity of the flow (we have current) at the most difficult conditions operation.
Installation speed without loss of connection quality.

We will proceed from this, because we often need the crimping of cable lugs, although we do not know anything about this. Although it seems simple:

Here we put the cable into such a little thing with a handle, we will properly squeeze the sides of the entrance, and it will be possible to screw this thing anywhere. By the way, such sleeves for crimping wires are sold anywhere, so you can buy them very inexpensively. Like a tool, because the lugs for wires for crimping with your own hands and pliers cannot be crimped.

So, for a one-time job, this will not be the most budget solution. Especially if you do not understand how crimping wires compares favorably with other cable methods.

First of all, wire crimping only applies to multicore cables. This should be borne in mind, since a reliable connection of one core, even with the most powerful mechanical loads, cannot be obtained.

The second is very important point. The number of cores matters, but the diameter of the cable does not. That is why the thinnest cables are crimped, the crimping forces of which are minimal.

And third. Crimping cable lugs is not possible without a special tool that is designed to perform this procedure.

And most importantly. What do we get as a result of pressing? We actually get cold welding» with the help of mechanical force of all cores of a crimped cable with a lug, without the use of soldering or other temperature effects.

This is the meaning of crimping wires - creating a strong connection quickly and without using the reliable switching method familiar to an electrician.

We just press the cable into the ferrule so hard that the connection becomes permanent. Well, the speed of installation, of course, is a significant factor for connections in electrical wiring. Even in crimping, there are limits to the applied force, so do not push the cable and lug too hard. Everything needs a measure.

Soldering a stranded wire is not the easiest operation, because you need to expose all the wires, make sure they are clean in terms of contact, and only then start soldering. Any core in a stranded wire has insulation, and this often creates difficulties in establishing reliable contact.

Just crimping the cable lugs solves all these problems, because with the help of mechanical force (compression), not only the insulation of individual cores is destroyed, but also a strong connection of the entire cable is created for better contact.

The problem is that the size of these sleeves is small, and the markings are incomprehensible to those who are not specialists. But before that, let's define the difference between a sleeve and a cable crimping lug.

These are typical sleeves:

With its help, you can "lengthen" the cable, both the same section and different.

And this is a typical tip:

And just in both photos it is clearly seen that there is practically no place for full marking, unlike such sleeves and tips:

Therefore, there can be only one recommendation - well-marked products will cost more, while unmarked ones are no worse. You just need to consult with the seller, as a rule, they are well versed in this issue.

different types

ring tips (NKI);
fork tips (NVI);
pin round tips (NShKI);
flat (plug) connectors (RPI-P, RPI-M, RSHI-P, RSHI-M, etc.);
piercing type couplers (OV).

Here it is necessary to return to the tool that provides crimping of wires, because each tool has dimensions for standard form sponges, and the force itself is accurately measured by diameters. So, if you didn’t make a mistake with the diameter, you won’t be able to apply excessive force.

And, despite the fact that the lugs for wires for crimping are different, with the same diameter and force, and the standard of the tool will be the same. It is a pity that this parameter is not reflected in the marking. Apparently because usually such work is done by professionals, not home electricians.

But it is the standards that allow home electricians to stock universal crimping pliers and without any problems to engage in crimping cable lugs for their own purposes. It is quite simple to master this procedure, and technologically it is the same for crimping an RG-45 connector and a tip for a three-phase machine.

When crimping a multi-core cable, special lubricants are indispensable. Therefore, use sleeves and tips that already have this lubricant inside. In any case, this is a one-time operation. It will not work to remove the sleeve or tip in order to rearrange it to another place.

As a result, having mastered the installation of sleeves and tips, you will be able to quickly restore the desired connection, carry out repairs without problems, as well as a connection that, in fact, will not need repair for many years.

For every inhabitant, a striking example of improper wiring is the stair switchboard, many apartment owners have melted wires in the switchboard, there are twists.

Ferrules for wires for crimping can save citizens from the possibility of heating and ignition electrical wiring as a result of poor-quality wire contact, the absence of cable lugs.

When there is good contact between the cable or wire being connected and the connection device, the transition resistance is minimized, and with an increase in current load on the contact group, they can heat up in case of poor contact.

Sleeves and tips are intended to remove or minimize the contact resistance, in other words, to eliminate poor-quality contact, for a bolt or screw.

High-quality contact in the connection, contact resistance:

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

copper tube

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

uncoated, TM - X - Y, where X is the cross section of the wire, Y is the size of the hole for fastening;
coated, TML-X-U.

There is another type of lugs with a control window, these are tinned copper products for terminating cable and wire cores. A 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 of the transition resistance.

Quite often in electrical engineering there is a connection of an aluminum wire with a copper cable, in this case it is recommended to use aluminum-copper lugs for high-quality connection of an aluminum wire and a shield copper bus.

Decreasing overall dimensions devices and devices, pin products have become popular tips for ending. 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 marked as NSHP.

Wire crimp - types

cylindrical shape;
forklifts;
loop;
connecting;
knife.

In addition, the crimping range is important, which shows the maximum and minimum cable cross-section. When working with wires with a diameter of 0.25 to 16 mm, use manual press tongs. They are suitable for laying and repairing computer networks, telephone lines and other low-voltage systems.

The crimping of car battery wires, cable lugs with a diameter of not more than 120 mm and the installation of substations are performed using a hydraulically driven tool.

For large volumes, it is advisable to use electric pliers, which can operate in automatic or semi-automatic mode.

Additional insulation. Usually, plastic is used to make tick handles, but some models also have rubber inserts. It does not conduct electricity and reduces the risk of electric shock.
Blade on the working part of the tool. It allows you to cut the cable and do without additional equipment.
If it is necessary to carry out crimping of sleeves of different sizes in in large numbers, then it is better to choose pliers with rotary dies or an adjustable punch.
Due to the design features, they can be used to work with wires of different sections. Crimping of tips of small diameter is carried out using pliers with curly jaws.

For crimping insulated and bare lugs, in order to fix them at the ends of wires of various sections, manual press tongs, called crimpers, are used. Crimpers are professional tools for electrical installation, and are produced by many manufacturers of hand tools.

With the help of pressing tongs, you can crimp the tips various types: ring, fork, pin, plug, sleeve and flat connectors, connector sleeves and other types of lugs.

The jaws of the pliers are called a matrix, there are special-shaped recesses on it for different diameters of crimped wires, flexible stranded and rigid single-wire, and, accordingly, for various tips.

Insulated lugs are suitable for stranded wires, bare lugs are suitable for single-wire rigid ones.

Tips as such are a convenient means of reliably connecting sockets, circuit breakers, UZO, lamps, switches, chandeliers, counters and many other devices.

For crimping conductors of a significant cross section, more than 16 square millimeters, hydraulic presses are used, but for the needs of professional electrical installation, manual press tongs and crimpers are also suitable.

Press tongs (crimpers) are different. There are specialized crimpers, for example, for crimping only 4P4C and 4P2C telephone jacks, as well as multifunctional ones, combining, for example, a stripper - a stripping tool. There are crimpers for fiber optic connectors, for D-sub connectors, etc.

A typical crimping crimper has comfortable plastic handles and a steel body and jaws. Such a device allows you to crimp the tip with one hand.

Particularly convenient are crimpers with a ratchet mechanism that blocks the opening until the end of the crimping of the tip is completed, so that undercrimping does not occur. If the crimping needs to be interrupted due to, for example, an error in the wire or ferrule diameter, the ratchet can be released manually.

Crimps often located on the jaws are marked different colors, for example, a crimp for a wire with a cross section of 0.25 to 1.5 sq. mm is marked in red, from 1.5 to 2.5 sq. mm in blue, from 4 to 6 sq. mm in yellow.

This is necessary so as not to get confused and not make a mistake with the diameter of the wire and with the tip. By the way, the insulated tips themselves also have colored cuffs of the corresponding colors.

The pressing process is quite simple. For example, you need to crimp the wire PuGV 1x4.0 sq. mm. To do this, take the necessary tip, for example, we need an annular one, and we chose NKI 6.0-4, which is suitable for wires with a cross section of 4 to 6 sq. mm.

First, the insulation is removed from the wire for the length of the tubular part of the tip to get the contact part, the wire strands are twisted a little, the tip is put on so that the wire protrudes slightly (about 1 mm) beyond the cuff, and the insulation rests against the metal.

The tip is installed in a matrix of press tongs, in our case - in yellow, and the crimp is carried out, holding the wire. There is an indentation along the profile of the tip into the wire. Then check the strength of the obtained crimping.

With the help of press tongs, you can crimp various connectors, crimp a variety of wires, and select any necessary lugs.

Among the extensive range of crimpers on the market today, every professional installer will easily select a tool for his profile. It can be a simple crimper or crimper stripper, multifunctional, or for only one type of connector, such as RJ45.

Crimping pliers for automotive terminals

Crimping pliers for auto wire terminals are an auto tool, thanks to which the wires inside the sleeve are well spliced and the cable is connected to the lug. The use of this tool in a car workshop significantly increases the speed and quality of work on repairing the electrical wiring of your car or your client.

Moreover, this tool is not limited to professional equipment, and therefore can be used for private car repairs in the garage.

Crimping pliers automotive terminals are divided into 2 varieties: diaphragmatic or functioning like ordinary pliers. The latter squeeze parts from 2 sides.

They have special holes on the jaws that allow you to correctly guide and adjust the repaired parts. These tools are considered universal, since they can be used to get to problem areas from different sides and projections.

Diaphragm crimping pliers adjust elements on 4 or 6 sides. More precise instrumentation properties depend on aperture functions. This mechanism provides a very tight cable crimp.

In addition, due to the features of the equipment, it can adapt to the sleeves different sizes which ensures its versatility.

But diaphragm crimping pliers have a certain disadvantage. They can only be used if the wires are inserted into the sleeve from one side. Otherwise, the pliers will be on the wire due to the structural features of their head.

Hydraulic hand press designed for crimping cable lugs and sleeves with a hexagon, with a cross section of up to 70 mm². Copper lugs and sleeves must not exceed a cross-sectional area of 50 mm².

Does the design have a pressure relief valve. Such products are more reliable, they prevent overloading the press from pressure.
Type of pressing head, which can be open or closed.

pre-open the stopper;
pull out the matrix;
put the wires and tip;
close the device.

And only after that you can start crimping the cable. For wires of small cross sections, the process is much simpler. If the press has an open type C-head, the wires can be pressed quickly anywhere.

Up to 70 mm².
Up to 120 mm².
Up to 300 mm².
Up to 400 mm².

With an increase in the power of the press, its mass increases. Some manufacturers reduce weight by using light aluminum alloys for the housing. All hydraulic presses are designed for crimping copper and aluminum wires.

Complete with a press there are replaceable dies for crimping. Most modern models, are equipped with rotating heads and fast travel device.

Inside the device, on the one hand, there is a working piston with a cuff - a spring is mounted to return it to its original position. On the other side, a pressure cylinder and a plunger are installed.

Main components hand press for tips

Pos. 1 - axis.
Pos. 2 - head.
Pos. 3 - matrix half-forms.
Pos. 4 - screw.
Pos. 5 and 6 - handles.

The pump plunger reciprocates.
The cylinder is pressurized.
Oil under pressure begins to flow into the working cylinder, moving the working piston.
The piston, acting on the matrix, creates the right pressure on the tip.
The design has a two-way plunger.
At idle, the circuit that provides rapid injection of fluid into the working cylinder is open. In the end idle move the second circuit begins to open, developing maximum effort.
The return spring, with the shut-off valve open, which connects the working cavity of the cylinder and the oil cylinder through the channels, returns the piston to its original position.
The crimping press for cable lugs is equipped with safety valve, which, when the pressure in the system is exceeded, begins to bypass a certain volume of oil back into the oil cylinder.

Handpiece manufacturing

What to do if you don't have special tools for crimping or just do not want to buy them if you need to crimp only one or two tips?

Many faced with this problem resort to wrong ways, which further only worsen the contact, not providing a reliable connection.

They begin to flatten the tip with hammers, simply squeeze it in a bench vise, crush it with pliers, and press it in with a chisel. All these methods are not correct and do not bring the desired result. After such amateur performance, poor contact is obtained with its further heating during operation.

True, some manage to compress the tip with a hydraulic press so that the wire quietly crawls out of it, it is worth pulling with a little effort.

There are other ways to crimp power wires with tips using improvised tools that can be found in almost everyone in a garage or at home.

The easiest and fastest way is to press in with a center punch.

ordinary hammer;
the tip itself, no matter what type and manufacturer;
vice or sledgehammer;
a center punch or, in extreme cases, a 200mm nail can be used once.

insert the tip into the wire;
put it on a hard surface - an anvil, vise, wide side of a sledgehammer;
and with uniform blows of the hammer on the center punch make point dents on the tip. First on one side, then on the other.

In this case, it is not necessary, as many do, to pre-flatten the tip with a hammer. In the process of strikes, this will happen anyway.
The number of cores, that is, holes from impact on the metal, depends on the length of the tip.

At the same time, on the reverse side of the tip, the crimping points should not be symmetrical with those on the front, but shifted by a couple of millimeters.

The most important thing is not to make a hole through the tip and control the impact force. Therefore, if you use a 200mm nail for this, you should first of all blunt it.

As a result, you will get sufficient contact, which, of course, cannot be compared with crimping with a professional PGR-70 tool, but in the absence of super-rated loads, it will last a long time. The most important thing in this method is to choose the right wires and tips. The declared cross section is very often less than the actual one.

For reliable contact, the wire must fit snugly inside the sleeve without any slack. That's why this moment always checked manually, do not blindly trust the numbers on the cable sheath and on the tip blade.

There are others simple ways connecting lugs to wires without using a press. For radio amateurs who do not have problems with solders and other devices, ordinary soldering is suitable.

This is not exactly a crimp, but it is still a connection method without the use of a special crimping tool.

The wire is tinned, the tip inside too. At the same time, in its upper part, where the blade is, a small hole must be drilled in the sleeve.
The stripped end of the cable is brought in, after which the entire structure (cable + tip) is wrapped with fiberglass tape.
Heated gas burner and molten tin begins to pour into the hole from above.
With constant heating with a burner, it will easily penetrate between the wire strands and the walls of the sleeve. The fiberglass will prevent the tin from flowing out.

Some do it even easier. They put tin inside the tip, heat the whole thing with a burner or even on gas stove and then insert the tinned cable there.

In order not to damage the insulation at the end of the wire, you can use a building hair dryer to warm up:

If you do not have soldering accessories, and you consider crimping with a dot using a center punch not reliable enough, then the third method remains.

Pick up a long enough threaded screw so that it overlaps the pressed part of the sleeve. The diameter of the screw should not be large, so as not to push through and crush the tip itself.

Position this screw along the tip. Then you compress the entire structure in a vice. As a result, you should get something like this form of pressing.

If one screw is not enough, a second one is superimposed over the depressed one and compressed again. You can initially use 2 screws, only installed on different sides of the sleeve. The main thing is not to overdo it and not break the sleeve.

To prevent the screw from moving, it can be fixed with electrical tape. In general, summing up, we can say that these three methods have the right to life, and many only connect wires this way power cable and tips.

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 are press tongs or crimpers designed for crimping sleeve, insulated, non-insulated lugs 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 to crimp both insulated and non-insulated ferrules.

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 have chosen the matrix and the tip, it seems to be correct, 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 specifications, 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 to optimal crimping conditions. 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 .