How to Safely Operate a Dieless Hydraulic Crimper

This step-by-step guide aims to empower users with the knowledge and skills necessary to operate a dieless hydraulic crimper safely. By following the outlined procedures, users can confidently and effectively use the crimper without compromising their safety or the quality of their work.

Top-Selling Hydraulic Crimping Tools


Inspect the crimper

Inspect the crimper before use:

  • Check all components: Examine the dieless hydraulic crimper for any signs of damage or wear. Inspect the body, handle, and jaws for cracks, dents, or any visible defects. Ensure that all parts are intact and properly aligned.
  • Inspect hydraulic hoses: Examine the hydraulic hoses for any signs of leakage, such as oil stains or wet spots. Check for any fraying, abrasions, or punctures on the surface of the hoses. Pay attention to any loose or damaged fittings.
  • Check connections: Verify that all connections, including those between the hoses and the crimper as well as any attachments, are secure. Ensure that fittings are tightened properly and show no signs of looseness or leakage.
  • Test for leaks: To confirm that there are no leaks in the hydraulic system, operate the crimper and observe if there are any fluid leaks during the process. Look for any drips or excessive fluid around the fittings or connections.

For example, if you notice any cracks on the handle or evidence of oil stains on the hoses, these may indicate potential issues with the crimper. Moreover, loose fittings or visible signs of leakage should be addressed before using the tool to ensure safe and effective operation.


Select the appropriate dies

To ensure that the correct dies are selected for the specific type and size of the terminal or connector being crimped, follow these steps:

  1. Refer to the manufacturer’s instructions or the crimper’s manual: These resources provide valuable information on the appropriate dies to use for different types and sizes of terminals or connectors. Check for a recommended die size chart or a list of compatible dies for the specific tool you are using.
  2. Identify the type and size of the terminal or connector: Before selecting the dies, it is crucial to accurately determine the type and size of the terminal or connector to be crimped. This can be done by inspecting the markings on the terminal or measuring its dimensions using a caliper or similar tool.
  3. Match the terminal or connector to a compatible die: Once you have identified the type and size, cross-reference this information with the die size chart or list provided in the manufacturer’s instructions or crimper’s manual. Look for the corresponding die size that matches the terminal or connector you are working with.

For example, if you are crimping a 14-16 gauge insulated female quick disconnect terminal, consult the manual to find the recommended die size. It might indicate that a specific die, such as the 16 AWG blue-coded die, is suitable for this application.

By following these steps and referring to the appropriate resources, you can ensure that you select the correct dies for your crimping needs, promoting proper connections and minimizing the risk of errors or damage to the terminals or connectors.


Prepare the crimper

To prepare the crimper, follow these steps:

  1. Secure positioning: Place the crimper on a stable surface, ensuring it is firmly secured to prevent any movement or wobbling during operation. This is important to maintain accuracy and safety while using the crimper.
  2. Connect hydraulic hoses: Attach the hydraulic hoses to the appropriate ports on the crimper. It is essential to match the hose fittings with the corresponding ports to ensure proper functioning. Double-check that the connection is secure to prevent any leaks or disconnections during operation.
  3. Power source connection: Ensure that the power source of the crimper is correctly connected. This may involve plugging the power cord into a reliable power outlet or connecting to a suitable power supply. Verify that the power source is functioning correctly by checking for any indicators or lights on the crimper’s control panel.

By following these steps, you can properly prepare the crimper for use, ensuring stability, proper hydraulic hose connection, and a functioning power source.


Position the terminal or connector

Position the terminal or connector into the crimper’s jaws by following these steps:

  1. Hold the terminal or connector securely with one hand, ensuring that it is clean and free from any dirt or debris.
  2. Open the jaws of the crimper fully by pressing the release lever or handle, making sure they are wide enough to accommodate the terminal or connector.
  3. Insert the terminal or connector into the open jaws of the crimper, aligning it with the designated crimping cavity.
  4. Close the jaws of the crimper carefully but firmly, ensuring that the terminal or connector is seated securely within the crimper.
  5. Verify that the terminal or connector is properly aligned within the jaws by checking that it is centered and not tilted or misaligned.
  6. Adjust the position if necessary, ensuring that the terminal or connector is securely and evenly seated in the jaws before proceeding with the crimping process.

By following these instructions, you can ensure that the terminal or connector is properly positioned and ready for crimping.


Activate the crimper

To activate the crimper, carefully follow the manufacturer’s instructions. Begin by locating the button or lever that is designated for initiating the crimping process. Once found, press or activate this button/lever to begin the crimping operation. It is crucial to pay close attention to any safety precautions outlined by the manufacturer, as these guidelines are put in place to ensure the user’s well-being and the proper functioning of the crimper. Always prioritize safety and carefully follow the manufacturer’s recommended steps to activate the crimper.


Monitor the crimping process

Monitor the Crimping Process

During the operation of the crimper, it is crucial to closely monitor the crimping process to ensure optimal results. Follow these steps to effectively monitor the crimping process:

  1. Observe Even Crimping: Pay attention to the terminal or connector that is being crimped and make sure that the crimps are even and uniform across the entire length. Irregular crimps can lead to poor electrical connections or even failure.For example, if you are crimping a wire terminal onto a cable, check if all points of the crimp are tightly secured and evenly compressed. Uneven crimps may result in loose connections, affecting the overall performance and reliability.
  2. Check for Excessive Force or Strain: Ensure that there are no signs of excessive force or strain during the crimping process. This includes:
  • Watching for any distortion or deformation of the terminal or connector during crimping.
  • Verifying that the crimping tool is not struggling or making unusual noises while applying pressure.
  • Ensuring the wire insulation is not being excessively deformed or damaged during the crimp.If you observe any of these signs, it is important to identify the cause and take corrective action, such as adjusting the crimping tool settings or replacing worn-out components.For instance, if you notice that the crimper is exerting too much force, it may indicate an incorrect adjustment of the crimping force setting. In this case, refer to the tool’s user manual to make the necessary adjustments for optimal crimping.

Remember, closely monitoring the crimping process is essential for producing reliable and durable electrical connections. By regularly checking for even crimps and avoiding excessive force or strain, you can avoid potential failures and ensure the utmost performance of your crimped terminals or connectors.


Inspect the crimped terminal or connector

Inspecting the crimped terminal or connector is an essential step to ensure the quality and reliability of the crimping process. Follow these instructions to thoroughly evaluate the crimped terminal or connector:

  • Visual Evaluation: Start by visually inspecting the crimped terminal or connector. Look for any signs of damage, including frayed wires, visible cracks, or bent pins. Ensure that the crimped terminal is securely attached to the wire, without any gaps or loose connections.
  • Measurement Verification: Check the measurements of the crimped terminal or connector against the required specifications. Verify the length, width, and height of the crimped portion to ensure it falls within the acceptable tolerance limits. Use precise measuring tools such as calipers or micrometers for accurate measurements.
  • Pull Test: Perform a pull test on the crimped terminal or connector to assess its strength. Apply a gradual force in the direction opposite to the crimped area and evaluate if it remains firmly attached without any signs of slipping or separation. A proper crimp should securely grip the wire, with no movement or detachment under the applied force.
  • Electrical Continuity: If the crimped terminal or connector is involved in electrical connections, test for electrical continuity using appropriate tools such as a multimeter. Ensure that there are no irregularities or interruptions in the electrical flow through the crimped terminal, which may indicate a faulty crimp.

By following these steps, you can ensure that the crimped terminal or connector meets the required specifications and is free from any damage or improper crimping.

Key Takeaways

To summarize, this blog post has provided a comprehensive guide on the safe operation of a dieless hydraulic crimper. By adhering to the instructions and prioritizing caution, individuals can ensure both their own safety and the prevention of any potential damage. Remember to always consult the manufacturer’s guidelines for further guidance. With these precautions in place, you can confidently utilize a dieless hydraulic crimper in a safe and efficient manner.

Necessary Equipment

  • Crimper
  • dies
  • terminals or connectors
  • personal protective equipment (PPE)

Efficient Techniques

  • Familiarize yourself with the user manual: Before operating a dieless hydraulic crimper, thoroughly read and understand the user manual provided by the manufacturer
  • Inspect the crimper: Before each use, carefully inspect the crimper for any signs of damage or wear. Pay attention to hoses, connectors, and the hydraulic system to ensure everything is in good working condition
  • Choose the proper crimping tool: Select the appropriate crimping tool for the specific task at hand, considering the type and size of connectors or fittings to be crimped. Ensure the tool is compatible and rated for the required pressure and size range
  • Wear protective gear: Always wear appropriate personal protective equipment (PPE) when operating a dieless hydraulic crimper. This may include safety glasses, gloves, and hearing protection, depending on the specific job requirements
  • Secure the workpiece: Place the workpiece securely in a stable position to ensure it remains steady during the crimping process. This helps prevent accidents and reduces the risk of damage to the crimper or connectors
  • Follow proper hydraulic pressure guidelines: Adhere to the manufacturer’s recommendations regarding hydraulic pressure settings. Over-pressurizing the hydraulic system can cause equipment failure or pose a safety hazard
  • Ensure proper dieless crimper positioning: Align the crimper tool jaws correctly with the connector or fitting being crimped. Use caution to prevent any accidental pinching or crushing of hands or fingers during the operation
  • Maintain a clean work area: Remove any debris, obstacles, or loose objects from the immediate work area to create a safe workspace. This helps prevent accidents and minimizes the risk of damage to the crimper or connectors
  • Use the crimping tool with proper care: Operate the dieless hydraulic crimper with care and attention, avoiding abrupt or excessive force. Apply steady and uniform pressure throughout the crimping process to ensure a secure and reliable connection
  • Regularly inspect and maintain the crimper: Conduct routine inspections of the crimper to identify any signs of wear or damage. Follow the manufacturer’s maintenance guidelines, including lubrication and cleaning, to keep the tool in optimal condition