EBCHQ 99315 - User Manual

This document describes the EBCHQ 99315 Hydraulic Crimping Tool, a professional-grade device designed for crimping copper and aluminum lugs. The manual provides comprehensive information on its features, technical specifications, operating instructions, maintenance, and safety guidelines.

Function Description:

The EBCHQ 99315 is a hydraulic crimping tool primarily used for connecting lugs and cables. It operates by applying hydraulic force to crimp various types of copper and aluminum lugs. The tool is designed for efficiency and high pressure, making it suitable for electrical construction sites. Its main crimping shape is hexagonal, with provisions for special shape designs through custom manufacturing. The tool's hydraulic mechanism ensures a strong and secure crimp, essential for reliable electrical connections.

Important Technical Specifications:

The manual details the specifications for two models, YQK-240 and YQK-300, though the 99315 model appears to align with the YQK-300 specifications based on the provided crimping range.

• Model: 99315 (likely YQK-300 variant)
• Crimping Range: Cu16-300mm² (for the 99315, YQK-300 lists Cu 10-300mm²)
• Crimping Force: 16T (16 tons) for the 99315, and 100KN (approximately 10 tons) for YQK-240/YQK-300. There appears to be a discrepancy between the 99315's listed force and the YQK models. Assuming 16T is the correct force for the 99315.
• Crimping Type: Hexagon crimping
• Stroke: 22mm
• Length: Approximately 500mm (for the 99315, YQK-300 lists approx 500mm)
• Weight: Approximately 6.30kg (for the 99315, YQK-300 lists approx 3.60kg). Another discrepancy, assuming 6.30kg is correct for the 99315.
• Package: Plastic box
• Weight of Box: Approximately 1.21kg (for the 99315, YQK-300 lists approx 1.20kg)
• Accessories:
  • Crimping Dies: 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300mm² (YQK-300 lists 10, 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300 mm²).
  • Sealing O-ring: One set

The tool's components include a latch, interchangeable crimping dies, a down die holder, a screw for releasing pressure, an active handle for operation, and a fixed handle for storing oil.

Usage Features:

The operating instructions emphasize safety and proper procedure:

1. Die Selection: Users must select the appropriate die set for the connector and cable being used. It is crucial to consult an authorized facility or distributor for proper die selection.
2. Die Insertion: Insert both upper and lower crimping dies into their respective holders, ensuring both halves are securely in place. The tool should never be operated without dies.
3. Cable Insertion: Fully insert the cable into the barrel of the connector.
4. Crimping Process: Place the connector between the dies. Pump the active handle repeatedly until the maximum pressure is reached.
5. Pressure Release: To release the pressure and retract the piston, spin the screw counter-clockwise.
6. Removal: Once the piston retracts, remove the crimped connector. The tool is then ready for the next cycle.

Safety Warnings:

Several safety precautions are highlighted:

• Work Area Safety: Keep the work area clean, well-lit, and free from distractions.
• Insulation: The tool is NOT insulated and must not be used on live conductors to prevent serious injury.
• Temperature and Corrosive Fluids: Avoid using or storing the tool under high temperatures or in environments with corrosive fluids, as this can age the sealing kits.
• Personal Safety: Stay alert, use common sense, and avoid operating the tool while tired or under the influence. Always use safety equipment such as masks, helmets, safety caps, and insulating shoes.
• Pinching Hazard: Never put fingers into the head of the hydraulic crimping tool during operation or when sliding dies, as severe pinching can occur.
• Tool Integrity: Do not knock any parts of the tool. Do not use the tool without dies. Only crimp copper or aluminum conducting material.
• Maintenance: Maintain labels and nameplates. Keep the tool out of reach of children.
• Oil Handling: Wear rubber gloves when handling oil. If oil touches skin, wash immediately with soap and water. Dispose of waste oil responsibly at an approved treatment center. Ensure no dust or air enters the oil when changing it, as this can damage the sealing kit.

Maintenance Features:

Proper maintenance is crucial for the tool's longevity and safe operation:

1. Pre-Use Inspection: Before each use, inspect the tool for loose screws, misalignment, binding of moving parts, cracks, or any other condition that might affect its safe operation.
2. Post-Use Cleaning: After use, clean the external surfaces of the tool with a clean, moist cloth. Apply rust-preventing oil to the metal surfaces of the tool and dies to prevent rust. Store the tool in a dry environment.
3. Professional Service: All service and repairs should only be performed by a qualified Service Technician. The manufacturer and/or distributor explicitly state that buyers are not qualified to make repairs or replace parts.
4. Sealing Kit Replacement: Over time, the sealing kits may become damaged, leading to leakage. If leakage occurs, contact the manufacturer or distributor for replacement sealing kits.

Oil Change Procedure:

The manual provides a visual guide for changing the oil:

1. Preparation: Spin out the oil plug and the fixed handle.
2. Piston Retraction: Fully retract the piston.
3. Draining Waste Oil: Fix the tool onto a bench vice and drain out the waste oil completely.
4. Filling New Oil: Fill the tool with new oil.
5. Air Exhaustion: Exhaust any trapped air and insert the oil plug.
6. Handle Re-insertion: Spin back the fixed handle.

Troubleshooting:

The manual includes a troubleshooting guide for common issues:

• No pressure or insufficient pressure:
  • Analysis: Pump lacks oil, dust in oil, or inner leakage.
  • Solution: Fulfill or replace oil, change oil, or contact manufacturer/distributor.
• Lug and wire not connecting tightly after crimping:
  • Analysis: Tool not reaching rated pressure or using the wrong die.
  • Solution: Refer to "no pressure" fault (A) or replace with the right die.
• Generating a lot of burs after crimping:
  • Analysis: Using the wrong die.
  • Solution: Replace with the right die.
• Oil leakage on the head or ram:
  • Analysis: Sealing kit broken.
  • Solution: Contact manufacturer/distributor and replace the sealing kit by a trained person.

The EBCHQ 99315 Hydraulic Crimping Tool is presented as a robust and efficient tool for electrical professionals, with a strong emphasis on proper usage and safety protocols to ensure both user safety and the longevity of the device.