Electrical Crimping Done Right

Working with electrical connections can be tricky, especially if you don’t have the right tools. A secure and reliable crimp is necessary for a proper connection, while a poor crimp can lead to eventual failure. That’s why having the right crimping tool – and using it properly – is crucial for performance and long-term reliability.

Crimping is more than just squeezing a terminal onto a wire. If crimping is done incorrectly, there could be air pockets in the crimp connection that can retain moisture. The moisture can cause corrosion, which can cause resistance, which can lead to heat and loss of conductivity.

The Right Tools for the Job

When it comes to crimping, you have a few tools to choose from depending on the application. For superior crimp quality, Kimball Midwest offers ratcheting crimpers. Unlike standard crimpers, which rely on user pressure, ratcheting crimpers provide a consistent, factory-quality crimp every time as they won’t release until the proper crimp pressure is reached. That means there is a consistent, reliable crimp every time, no matter who is using it.

The Ratcheting Insulated Terminal Crimp Tool is perfect for standard insulated terminals. In addition to the superior crimp quality it provides, it also features a powerful four-ratchet pawl design for increased leverage, adjustable tension control, multiple crimp stations and cushion grip handles.

The Ratcheting Heat Shrink Terminal Crimp Tool is designed specifically for heat shrink terminals. This tool has rounded crimp stations to prevent cutting or damaging a terminal’s heat shrink insulation. It also features self-aligning jaws, four color-coded crimp stations and an ergonomic design.

Kimball Midwest also has non-ratcheting crimpers, such as our Techni-Crimp Terminal Crimping Tool. This tool features twin precision wire cutters, one up front for close quarters work and the other above the strippers for easy use together. It also has built-in dies for insulated and non-insulated terminals.

For heavy-duty applications with battery terminals and lugs, a hydraulic crimper like our Hydraulic Assisted Battery Terminal and Lug Crimpers (27798 and 27799) provides power and precision.

They feature hand-operated hydraulics, which uses the power of hydraulics to create factory-style crimps quickly and easily. Both also have versatile die sets to handle a wide range of battery terminals and lugs and feature a quick-change design so dies can be removed or installed in seconds.

Make the Right Crimp

A successful electrical connection starts with a properly executed crimp. Follow these steps to secure a reliable crimp:

1. Select the proper terminal for the application and wire size used.
2. Strip the wire to the proper length. Plan your strip length so that at least 1/32” of wire can be seen protruding from the end of the terminal barrel.
3. Choose the correct crimp tool for the terminal type.
4. Select the proper crimp nest for the terminal and wire size used.
5. Perform the crimp. Position the terminal in the crimp tool to ensure the tongue is level with the crimp nest.
6. For nylon-insulated terminals, perform a second crimp on the flared barrel of the insulation housing for added strain relief against vibration and wire pull-out.
7. For non-insulated terminals, select the proper crimp nest or spiked portion of the tool marked for non-insulated terminals. Crimp on the side opposite the seam to prevent spreading the barrel.

A proper crimp is key to maintaining safe and efficient electrical connections. No matter what electrical job you are working on, the right crimp and tool makes all the difference.

Need help crimping or selecting the right products for the job? Contact your Kimball Midwest sales representative today. If you don’t already have a rep, we can help you