tricab ALI-FLEX B24 User manual

(*) In case of using dies with different length of crimp face from specified above, the total effective crimp length
(crimp length x no. of crimp) should be equivalent or greater to maintain a secured mechanical and electrical
connection.
This Installation Guide was designed with great care and proper testing before publication to ensure the product works perfectly with TriCab
flexible cables. ALI-FLEX® Aluminium Crimp Links are specifically designed, tested and certified for use with TriCab ALI-FLEX® cables only.
TriCab is not liable for any errors, omissions, damages etc. due to improper use of this product, included but not limited to improper
installation deviating from this Guide, safety and warning rules violation, using unsuitable cable other than TriCab flexible cable. TriCab
reserves the right to modify this Installation Guide at any time without prior notice.
www.tricab.com
1
TCIM-ACC-B24 Rev. 01
B24 ALI-FLEX® Aluminium Crimp Link
Installation Guide
Conductor
Size
Die A/F
mm² mm 12-13 tonne 60 tonne mm mm
16 9.0 1 Crimp x 22.0mm 32
25 9.0 1 Crimp x 22.0mm 32
35 13.2 1 Crimp x 22.0mm 32
50 17.3 1 Crimps x 22.0mm 60
70 17.3 1 Crimps x 22.0mm 60
95 17.3 2 Crimps x 22.0mm 60
120 22.0 2 Crimps x 22.0mm 60
150 22.0 2 Crimps x 18.0mm 60
185 28.4 2 Crimps x 18.0mm 60
240 28.4 2 Crimps x 18.0mm 60
300 39.0 1 Crimp x 50.0mm 70
400 39.0 1 Crimp x 50.0mm 13 70
500 43.2 1 Crimp x 50.0mm 70
630 43.2 1 Crimp x 50.0mm 70
13
B24 SELECTION TABLE - ALI-FLEX CRIMP LINK Crimp Distance
from Dimple Edge
Use Adaptor and
Standard 12 Tonne
Dies 10
Stripping Length of
Cable Insulation
Hydraulic Tools - Hexagonal Die
No. of Crimp x Crimp Face Length*
Aluminium Barrel
Dimple

This Installation Guide was designed with great care and proper testing before publication to ensure the product works perfectly with TriCab
flexible cables. ALI-FLEX® Aluminium Crimp Links are specifically designed, tested and certified for use with TriCab ALI-FLEX® cables only.
TriCab is not liable for any errors, omissions, damages etc. due to improper use of this product, included but not limited to improper
installation deviating from this Guide, safety and warning rules violation, using unsuitable cable other than TriCab flexible cable. TriCab
reserves the right to modify this Installation Guide at any time without prior notice.
www.tricab.com
2
TCIM-ACC-B24 Rev. 01
B24 ALI-FLEX® Aluminium Crimp Link
Installation Guide
Select a suitable size of ALI-FLEX® Aluminium
Crimp Link by verifying that the conductor size
marking on the lug and cable match.
Mark stripping length on cable as specified on the
B24 Selection Table.
1.
2.
3.
4.
7.
5.
6.
Carefully cut and strip outer layers of the cable
(sheathing, insulation, fleece tape). Be very careful
not to nick or cut any strands of the conductor.
Adjust the stripping tool so that it cuts close to the
conductor but leaves a small amount of insulation to
tear away by hand. This will help protect the fine
wires during the stripping process.
Carefully insert the conductor into the lug making
sure all strands are contained within the barrel. Do
not twist the conductor.
Select a suitable crimping tool with the correct crimp
force and note the required No. of crimps as specified
on the B24 Selection Table (12-13 Tonne or 60
Tonne). Choose the appropriate Aluminium die by
referring to the correct A/F (across flats) die size on
the B24 Selection Table. The correct A/F size is also
printed on each B24 link. Please note that the mm²
cable size markings on AF dies from brands other
than TriCab, have no relationship to the mm² cable
sizes for ALI-FLEX cables.
Check crimping result. Us a file if necessary to
remove burrs to have a smooth crimp surface.
Apply suitable ALI-FLEX® G03 Glue Lined Heat-
shrink over the entire link to complete the crimping.
Two layers of the heatshrink should be applied if
the link is outside an enclosure. The heatshrink
should cover both barrels and approximately 50mm
of the cable jacket on either end.
For hydraulic hex crimpers, place the lug on the non-
moving die and allow the other die to move up to
crimp. If more than 1 crimp is required (refer B24
Selection Table for more details), begin crimping
from the center (dimple end) of the barrel to the
open end. Position the lug to the correct crimp
location on the barrel as specified on the B24
Selection Table. Do not crimp closer than 10mm from
the dimple at the center.
Begin the crimping process and continue until the full
cycle is complete. Make sure the dies are fully closed
for sufficient crimping force. Release the ram and
repeat the process if more than 1 crimp is required.
Leave a 7mm gap between each crimp. Do not crimp
closer than 4mm from the open end of the barrel.
8.
Repeat Steps 1-6 for the other end of the barrel.
Min 10mm
Correct Crimp Position
Center of Barrel
Crimp Position is too close to dimple
Min 10mm
Min 4mm 7mm
Correct Crimp PositionCrimp Position is too close to dimple