No.1

Basic Guide toTerminal Crimping

Have you ever experienced wire snap, wire slip-off or insulation
deterioration because you used the wrong crimping tool or installation method?

１Selection Process
Wire Size

TerminalTool① The correct terminal size is dictated by the size ofb l e Wire Si ze

Each Terminal has an acceptable wire size range

5ce p t acA

5.

1.

252

8

the wire you are using.

1.0mm2

Table of Contents:
1.5mm2

How to Select a Terminal

R 1.25-4

Both Terminals
accept the size

1.25mm2

0.25~1.65mm2
R 2-42mm2

How to Crimp a Terminal
How to Select the Correct Assembly Tool

2.5mm2

1.04~2.63mm2

If the wire size is below the range, it may cause the wire toslip out of the terminal. Example: select R2-4 for 1.0mm2 .
NOTE If you select a terminal too small for the wire the wire may split
the barrel. An example of this would be if you selected a R1.25-4
terminal to use with a 2.5mm2 wire.

No.2
DO NOT CRIMP AN INSULATED TERMINAL USINGA TOOL FOR NON-INSULATED TERMINALS.

② How to Select the Correct ToolYou should select the tool based on the size
and type of the terminal you are going to use.
terminal

The crimp will split the insulator and expose the metal
which can cause an electrical short circuit.

Tool Selection

Non-Insulated Terminal

SingleJaw
DO NOT CRIMP AN INSULATED TERMINAL WITH
A SOLID COPPER WIRE INSERTED.
Crimp the center of the barrel by theindentor

Only stranded copper wire is acceptable. For solid copper wire
select the non-insulated terminal and add an insulation cap.

Insulated Terminal

DoubleJaws

Insulated Terminal
Crimp the center of the barrel and theinsulation at the same time as shown left.

２CRIMPING INSTRUCTIONSStrip the Wire

Close EndSingleJaw

Strip the wire to be crimped according to theinstructions for each wire type.
The length of the insulation
to be removed is dependanton the terminal type andshape used.

Crimp the center of the crimp barrel
as shown left.

No.3

Wire is passed the barrel.
Wire insulation does not touch the barrel.

5m

Approx:1mm

Combine the tip of theconductors by making
sure the ends are evenand twisting withpliers 2-3 times

８２2mApprox:1mm

1.25

Non-Insulated Parallel Connector
0.75.5a

The terminal isplaced in the nest at
the point marked
1.25.

２ｍｍ２8(a)＋（1.5〜3.5mm）

２Use the Non-Insulated Terminal
Crimping Tool (NH 1)
2

The conductor should extend approx.
1.5-3.5mm from the end connector.

5Approx:1mm★ Select the die for the crimping tool according to the terminal size
Example R1.25-4８ｍｍ

1.2Open End Connector

5.5

Non-Insulated Terminal② Crimping Instructions Continued

１．
２５ｍｍ２Use the appropriate wire sizefor 1.25mm2 terminals.(0.25mm2~1.65mm2)

３.５・５．
５ｍｍ２8

Approx:1mm

2Approx:1mm

28

Non-Insulated Butt Connector

Closed End Connector
The length between the sleeve and theend of the insulator varies by type.
Strip each wire to reach the end of theinsulator.

Insulated Terminal
Approx:1mm

55.

1.

55.

1.

2525

Cover the crimped end
connector with insulation tape

Place the terminal in the nest with thebrazed seam facing the indentor.

Close the handles slightly for theterminal to be retained by the die.
Next insert the stripped wire intothe terminal barrel.

Squeeze the handles until
they release.

Easy Entry Method
Our insulator has a funnel shaped wire entry
for faster and easier wire insertion

RatchetAllow the handles
to open.

Funnel Entry
Example of Part Number
TMEX 1.25-4

DO NOT REMOVE THERATCHET.
The ratchet mechanism
avoids insufficient crimp.

RatchetNo.4

CRIMPING INSTRUCTIONS FOR INSULATED TERMINALThe tool for the insulated terminal has double jaws. One jaw crimps thewire barrel and the other crimps the insulation.
Do not put the terminal
in backwards!

NON INSULATED TERMINALINSULATED TERMINALCROSS SECTIONAL AREA

CROSS SECTIONAL AREA

Locator: Helps to fix a good crimp position.

2502.

1.

30.
50.

Non-Insulated Parallel
Connector

Insulated Terminal

Non-insulated
Butt Connector

Insulated Butt Connector

NH 32

Remove the locator when crimping insulated sleeves,pin and disconnects.

Using the wrong dies or reversing the terminal placement
will cause insufficient crimping.
Insufficient crimping may cause wire slippage.

Narrower

Wider③ Inspection
Thinner Width(Dies for wirebarrel)

Thicker width(Dies for insulatorbarrel)

NoN
INSULATED TERMINALINSULATED TERMINALJUDGEM MENTGood Crimp

CRIMP THE CENTER OF THE WIRE BARRELWRONG

Indentor
WRONG

WRONG

Nest

Rear Crimp may
cause Wire Snap

Front Crimp may
cause Wire Slip

WRONG

No.5

３

TOOL SELECTION INSTRUCTIONSLARGER NON-INSULATED TERMINAL COMPRESSION TERMINAL
T - CONNECTOR
Crimping of larger terminals is accomplished by using a hand hydraulic tool,
battery operated hydraulic tool or combination of crimp head and hydraulic pump.

For non-insulated terminals
Non-insulatedterminal● NH 1395g／235mm● NH 69

Applicable terminal sizes :1.25mm2 ~8mm2250g／180mm

Battery operated
hydraulic tool

Applicable terminal sizes : 0.3/0.5mm2 ~2mm2
SHORT HANDLE

Hand hydraulic tool
Crimp Head
T-Connector

Open End Connector● NHE 4 410g／240mm
Applicable Part Numbers : E-S, E-M, E-L

Hand hydraulic tool
Compression
Terminal

Crimp Head

Motor Driven
HydraulicPump

Motor Driven
HydraulicPump

For Insulated Terminals● NH 32 450g／240mm
Applicable terminal sizes : 0.3/0.5mm2 ~ 2mm2
PNEUMATIC TOOLNA 10

ICT PNEUMATIC / ELECTRIC CRIMP MACHINE

NA 20

NC A 100
NCM 100

For Closed End● NH 38 430g／250mm
Applicable terminal sizes : CE 1 / CE 2 / CE 5 / CE 8

non-insulated terminals
0.3/0.5 ~ 5.5mm2
Insulated Terminals
0.3/0.5 ~ 5.5mm2※The tools may be subject to model change

Applicable terminal sizes
non-insulated terminals
8 ~ 60mm2

non-insulated terminals
0.3/0.5 ~ 5.5mm2
Insulated Terminals
0.3/0.5 ~ 5.5mm2