Crimp Tool Reference Data Sheet; Crimping Instructions; Terminal Loading; Terminal Crimping - Power Signal Group Hand Crimp Tool User Manual

Crimp Tool Reference Data Sheet

Power & Signal Group supplies specific required information with each shipment of its pre-assembled hand crimp tools
and with individual die inserts. Information includes terminal part number, cable type, strip length, and other information
relevant to obtaining a quality crimped terminal. Additional validation data is available upon request.

Crimping Instructions

The proper inserts, terminal locator and wire stop should always be used for the intended terminal and wire gauge size
(See Crimp Tool Reference Data Sheet).
• Reference tool number, terminal name and wire gauge sizes on tool parts.
• Reference terminal part numbers and cable gauge sizes from authorized wiring prints or other documents.
• Use the specific cable strip length from the Crimp Tool Reference Data Sheet.

Terminal Loading

Insert loose piece terminal into holder opening as shown in Figure 1. Type 2 (Pin & Sleeve Terminal) locators must be
opened with knurled wheel and closed to orient terminal so as to capture terminal wings. Use correct cable seal if
required (Figure 2).
Figure 1
Make sure terminal is fully inserted so wings are over the crimp anvils. If wings do not catch properly,
slightly bend inward to clear upper plate. Partially close ratchet handles to capture terminal. (Use
wrench to turn square nut clockwise to release handles if terminal is not captured properly.)
Position stripped wire end against wire stop in bottom of crimp wings for Type 2 or in upper die for
Type 1. Make sure the spring loaded wire stop returns after each crimp. (If wire stop does not return,
the locking nut is too tight or the stop needs to be lubricated.) If a cable seal is used, make sure the
seal is positioned so that the insulation wings capture the seal. Make sure no strands are cut or are
missing in the stripping process.

Terminal Crimping

Complete the ratcheting closure of handles until they spring open. Remove crimped leads carefully.
Inspect crimped lead according to the Visual Crimp Quality Recommendations to eliminate nonconformances:
Measure all crimp dimensions with calibrated measuring equipment. Compare to crimp dimensions supplied with the
tool inserts for specific cable size and terminal part number.
If crimps are too high, remove set screw and turn serrated wheel counterclockwise (+) until proper crimp height is
achieved. (Reinsert screw before trying again.) If core crimp height is too tight, follow the same procedure except turn in a
clockwise direction.
6
Figure 2