12:4 Use and safety instructions Instructions and directions Elpress hydraulic and mechanical tool systems are some of the safest on the market. Safety requires that instructions and directions are available and followed closely. Each Elpress tool is therefore accompanied by detailed instructions on how to use the tool. These instructions should be read carefully before use, in the best interests of the operator. Correct use of the tools: • increases productivity • increases tool life • ensures the quality of work done • minimises the risk of accidents Safety rules Below are some simple and common rules that we at Elpress recommend all operators to follow: • Before starting work with a crimp tool, a thorough visual inspection should be carried out. Pump, crimp head, forks, couplings, hoses and other accessories must be checked to ensure that they are faultless and clean. The correct placement of the inserts in the forks should also be checked before starting work. • All operators must wear personal protective equipment such as A51 gloves, goggles and safety shoes. • Hydraulic pressure must not be applied to a hose that is heavily bent or knotted. The hose is made for particularly high pressure and cannot be replaced by another type. • Hydraulic tools must never be carried in the hose or coupling. • Operate with caution, do not drop heavy objects on the hydraulic hose. This can damage the steel reinforcement and cause leakage. If leakage occurs, oil under high pressure may come into contact and penetrate the skin resulting in internal injury. If this happens, contact a doctor immediately. • The tools must be serviced and calibrated at regular intervals. • Make sure that the correct tool or tool insert has been selected for the terminal and conductor to be crimped. • Check that the installation is unpowered before carrying out work. The tools are not designed for “Live working”. • Keep in mind that there is very high crimp pressure during work. Therefore, never stand in front of a tool in the direction of crimping force. • Pay attention to the risk of crushing and cutting injuries during work. This applies to all types of crimping tools and cable cutters. • If there is a suspicion of failure of a crimp system, always contact the Elpress Service Centre. Check of crimping results In order to ensure that the tool has achieved the predetermined shape change for each cable terminal, the crimp result shall be measured. This shape change provides both mechanical strength and good electrical properties. Hexagonal crimping For terminals and through connectors of copper the following applies: • The ”N” dimension is checked in the direction of the crimp. • Measure with calipers and compare with the table’s ”N” dimensions. • If the measurement result exceeds the ”N” dimension (according to the table that follows) after correct contact crimping, contact the Elpress service centre. Crimp die table type KRD/KSD (N-measurement) Type KRD/KSD with B-dies KRD/KSD Die No. max N mm 16 8 6.3 25 9 7.3 35 11 8.8 50 12 10.2 70 14 11.6 95 16 13.0 120 19 15.0 (KB dies) 120 19 15.2 150 22 16,3 185 25 20.1 185 25 20,3 (CB and KB dies) 240 27 20.5 300 30 23.3 400 32 24.5 Crimp die table type KRT/KST (N-measurement) Type KRT/KST with B-dies KRT/KST Die No. max N mm 10 7 5.9 16 8.5 7.5 25 10 8.2 35 12 10.2 50 14 11.6 70 16 13.0 95 18 14.0 95 18 13.8 (KB dies) 120 19 15.0 (KB dies) 120 19 15.2 150 22 16.3 185 24 17.7 240 26 19.5 300 30 23.3 400 32 24.5 Crimp die table type KRF/KSF with Dual dies (N measurement) Type KRF/KSF with DUAL dies KRF/KSF DB-die nr max N mm 10 8 6,7 16 9 7,5 25 11 9,0 35 13 10,6 50 14,5 11,8 70 17 13,6 95 20 16,0 120 22 17,7 150 25 20,3 185 27 21,7 240 30 23,9 300 32 25,7 400 38 30,5 Crimp die table type KRF/KSF (N-measurement) Type KRF/KSF with B-dies KRF/KSF Die No. max N mm 10 8 6,3 16 9 7,3 25 11 8,8 35 13 10,2 50 14,5 11,2 70 17 13,4 95 20 16,4 95 20 15.8 (TB die) 120 22 16,3 150 25 20,1 150 25 20,3 (CB and KB dies) 185 27 20,5 240 30 23,3 300 32 24,5 400 38 30,3 500 42 30,4 630 53 38,4 800 53 38,4
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