KIMBALL MIDWEST 27-798 Instruction Manual

Read through this Operating Instructions Manual carefully before using the product. Protect yourself
and others by observing all safety information, warnings, and cautions. Failure to comply with
instructions could result in personal injury and/or damage to product or property. Please retain
instructions for future reference.
High-Capacity
Cable Crimper
Operating Instructions Manual
27-798

2
It is the owner and/or operator’s responsibility to study all warnings, operating and maintenance
instructions contained on the product label and in the instruction manual prior to use of this product.
The owner/operator should retain product instructions for future reference.
The owner and/or operator are responsible for maintaining all decals or warning labels while in use,
maintaining the unit in good working order and performing all general maintenance of the product.
If the owner and/or operator are not uent in English, the product warnings and instructions shall be
read and discussed with the operator’s native language by the purchaser/owner or his designee.
Make sure that the operator comprehends its contents. Safety information shall be emphasized and
understood prior to usage. The product shall be inspected per the operating instructions. Users of
this product must fully understand these instructions. Each person using this product must also be of
sound mind and body and must not be under the inuence of any substance that might impair their
vision, dexterity or judgment.
Protect yourself and others by observing all safety information.
Failure to comply with instructions could result in personal injury and/or property damage.
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
This manual is intended for your benet. Please read and follow the safety, maintenance and
troubleshooting steps described within to ensure your safety and satisfaction. The contents of this
instruction manual are based upon the latest product information available at the time of publication.
The manufacturer reserves the right to make product changes at any time without notice.
Help protect yourself and others from injury - read, follow, and save these important safety
precautions and operating instructions.
Read and understand all instructions. Failure to follow these safety precautions and operating
instructions could result in severe personal injury, property damage or death.
READ BEFORE USING
IMPORTANT SAFETY INSTRUCTIONS

3
GENERAL POWER TOOL SAFETY WARNINGS
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when operating this tool. Do
not use a tool while you are tired or under the inuence of drugs, alcohol or medication. A
moment of inattention while operating tools may result in serious personal injury.
2. Use personal protective equipment. Always wear eye protection. Protective equipment
such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
3. Do not overreach. Keep proper footing and balance at all times.
4. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves
away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
5. Do not force the tool, use the right tools for your application.
6. Store idle tools out of the reach of children and untrained users.
7. Maintain hydraulic crimper; check for misalignment or binding of moving parts, breakage of parts
and other conditions that may affect the hydraulic tool’s operation. If damaged, please have the
hydraulic tool repaired before further use. Many accidents are caused by poorly maintained tools.
8. Use the hydraulic crimping tools and accessories in accordance with these instructions and in the
manner intended, taking into account that operations different from those intended could result in a
hazardous situation.
READ ALL SAFETY WARNINGS AND ALL INSTRUCTIONS.
Failure to follow the warnings and instructions may result in electric shock, re
and/or serious injury.
IMPORTANT SAFETY INSTRUCTIONS
ELECTRICAL SAFETY
Switch off breaker to power source whenever working
on connected electrical wiring.
An incomplete crimp can cause a re.
• Use proper connector and cable combinations. Improper combinations
can result in an incomplete crimp.
• The handle load will drop suddenly to indicate a completed crimp. If the
handle load does not drop suddenly, the crimp is not complete.
Failure to observe these warnings could result in severe injury or death.

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Number Name Remark
1 Die For crimping, interchangeable crimping die
2 Crimper Head For holding dies
3 Thumb wheel For retaining and releasing oil pressure
4 Active handle For operating
5 Fixed handle For storing oil
1
2
3
4
5
SPECIFICATIONS & COMPONENTS
SPECIFICATIONS & COMPONENTS
Crimping range: Copper: AWG #6-4/0 (10-120 mm²)
Crimping force: 15,736 Lbf (70kN)
Crimping type: Hexagon crimping
Crimping stroke: 0.55 in (14 mm)
Oil type: ISO 15 Hydraulic mineral oil
Oil storage Capacity: Approximately 1.69 oz (50 ml)
Dimensions: 16.3 in x 2.68 in x 4.72 in (414 x 68 x 120 mm)
Standard dies: AWG# 6, 4, 2-1, 1/0, 2/0, 3/0, 4/0
(16, 25, 35, 50, 70, 95, 120 mm²)

5
OPERATING INSTRUCTIONS
READ ALL SAFETY WARNINGS AND ALL INSTRUCTIONS.
Failure to follow the warnings and instructions may result in electric
shock, re and/or serious injury.
Select the appropriate die set. It is recommended to consult a qualied professional for proper compression die
set for the connector, copper tube sleeve end and cable being used.
DO NOT operate crimper without dies completely set into
crimper head.
1. Remove the latch pin from
the tool head. (Fig 1)
2. Insert the lower die into the groove of the
tool head. (Fig 2)
3. Put the cable into the tool head. (Fig 3)
4. Insert the upper die into the groove of the
tool head.
5. Insert the latch pin into the the tool head,
ensuring it is fully seated.
6. Fully insert the stripped cable end into the
barrel of the connector. (Fig 4)
7. Place the connector between the dies.
8. Make sure both die halves are secured
before operating the tool to compress the
connector.
9. Rotate the thumb wheel in the clockwise
direction to close the valve.
10. With the connector and cable properly
positioned between the dies, pump the
handle to compress the connector.
11. Rotate the thumb wheel in the counter-
clockwise direction to open the valve and
retract the piston.
12. Remove the completed workpiece. If
necessary, remove the latch pin from the
tool head to remove nished cable.
The tool is ready for the next cycle.
Fig 1
Fig 2
Fig 3 Fig 4

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OPERATING INSTRUCTIONS
Best
Corners should
be as crisp
and sharp as
possible.
Acceptable
Corner radius
should be shorter
than the length of
the at sides.
Too Loose
Die size is
too large.
Select a
smaller die.
Over-Crimped
Die size is too
small. Select a
larger die.
Crimp Quality Diagram
AWG Cast Copper Battery
Terminals and Lugs
Copper Tube Lugs
Recommended Die (mm2) Recommended Die (mm2)
6 35 16
4 35 25
1-2 50 35
1/0 70 50
2/0 70 50
3/0 95 95
4/0 120 120

7
OPERATING INSTRUCTIONS
HOW TO CHANGE THE OIL
1. Spin out
xed handle.
2. Remove
oil cap.
2. Fully
retract
piston.
3. Drain out
oil waste.
4. Fill with
clean oil.
5. Close oil
cap.
6. Close xed
handle (Turn
clock-wise).
Dust or air inside the tool will damage the sealing kit and
cause the oil to leak. Make sure the oil is clear of debris when
changing oil. Wait for a while and exhaust the oil completely out
of the oil tube before inserting the oil plug.
Please wear rubber gloves to avoid skin touching the oil
directly. Please wash hands with soapy water after handling oil.
Properly dispose of waste oil according to local regulations.

8
MAINTENANCE AND SERVICE
TROUBLESHOOTING
Damaged equipment may cause injury.
1. Inspect hydraulic crimper before operating. Check for loose screws, misalignment or binding of
moving parts, cracked or broken parts, or any other condition that may affect its safe operation.
2. Tool care and storage. Clean external surface of the tools with clean towel. Apply rust preventing
oil on the metal surface of the machine and the dies to avoid rust. Store the tool in a dry
environment.
3. Service requires a qualied service technician.
4. In order to prolong the tool’s working life, please change the oil regularly. Take care to avoid
dust and debris in the oil reservoir.
5. Always store tool with the piston in the retracted position.
6. The original seals may fail after many uses. If leaks develop replace the sealing rings.
PROBLEM POSSIBLE CAUSE LIKELY SOLUTION
P1. No pressure or the
pressure is not enough
during operating.
1. The pump lacks enough oil.
2. There is dust in oil.
3. Internal leakage.
1. Fill with oil.
2. Change the oil.
3. Contact manufacturer or distributor.
P2. The lug and wire do
not connect tightly after
crimping work.
1. The tool can not achieve the
rated pressure.
2. Use of wrong die set.
1. Refer to the fault P1.
2. Replace with the right die set.
3. Consult a qualied professional.
P3. Generates a lot of
burs after crimping work.
1. Use of wrong die set. 1. Replace with the right die set.
2. Consult a qualied professional.
P4. Oil leakage on the
head or ram.
1. O-ring(s) deteriorated. 1. Replace deteriorated O-ring(s)
2. Have serviced by qualied
professional.

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PARTS LIST
No. Description Qty
1 Die 1
2 Bolt 1
3 Spring 1
4 Pin 1
5 Latch 1
6 Head 1
7 Spring 1
8 Piston 1
9 Plastic retainer ring 1
10 O-Ring 1
11 Steel ball 1
12 Steel ball 1
13 Spring 1
14 Valve 1
15 Post 1
16 Copper gasket 1
17 Bolt 1
18 O-Ring 1
19 Plastic retainer ring 1
20 Plunger 1
21 Pin 1
22 Retainer ring 1
23 Active handle 1
24 Handle sleeve 1
25 Bolt 1
26 Screw 1
27 O-Ring 1
28 Plunger 1
29 Steel ball 1
30 Pin 1
31 Cylinder 1
32 Valve 1
33 Spring 1
34 Steel ball 1
35 Fliter 1
36 Fliter sleeve 1
37 Plastic retainer ring 1
38 O-Ring 1
39 Oil tube 1
40 Plug 1
41 Fixed handle 1
42 Handle sleeve 1

NOTES

NOTES

Kimball Midwest warrants to the original buyer (“Buyer”) all parts and accessories purchased by it from Kimball
Midwest against defects in material or workmanship.
Kimball Midwest will repair or replace, at no charge to the buyer, this tool which, after examination by Kimball
Midwest, is determined to be defective within a period of 30 days from receipt.
Coverage under this warranty will be provided only if the defective tool has been submitted to Kimball Midwest for
inspection.
This warranty does not cover any damage to this tool due to alteration, modication, improper installation, accident,
post-installation misuse, abuse, negligence, inadequate maintenance, or malfunction of associated parts or
equipment not supplied by Kimball Midwest.
This warranty is in lieu of any other warranty, expressed or implied, including any warranty of merchantability or
tness for a particular purpose. Replacement or repair as provided under this warranty is the exclusive remedy of
the buyer. Kimball Midwest shall not be liable for any incidental or consequential damages resulting from breach
of this warranty. Kimball Midwest neither assumes, nor authorizes any person to assume for it, any other liability in
connection with the sale of its products.
If this Kimball Midwest Product proves defective in material or workmanship within 30 days after purchase, contact
the Kimball Midwest Quality Assurance Department at [email protected]
Manufactured for:
Kimball Midwest
4800 Roberts Rd.
Columbus, OH 43228
1-800-233-1294
www.kimballmidwest.com
ONE YEAR LIMITED WARRANTY
LIMITED WARRANTY