Expt No.

Date:

PREPARE TERMINATIONS- CRIMPING LUGS WITH CABLE ENDS

OBJECTIVES

At the end of this exercise you shall be able to

Use the crimping tool to crimp pressure terminal(lug) at the cable end

Requirements:

Tools/Instruments

Pressure pliers 200mm 1No

Electricians knife 100mm 1No

Wire stripper (manual) 200mm 1No

Combination pliers 200mm 1No

Crimping pliers150/200mm 1No

Wire stripper auto-ejrct 200mm 1No

Steel rule 300mm 1No

Side cutting pliers150mm 1No

Eyelet closing pliers 200mm 1No

with former for eyelets having inner
dia.
of 3,4,5,6,7 mm

MATERIALS

Cables

Compression connectors

Crimping eyelet, eye hole dia 6mm 12Nos

Crimping ferrulr 4mm ,10mm lon g 6Nos

Crimping spade lug 6A 6Nos

Crimping spade lug 10A 6Nos

Crimping spade lug 16A 2Nos

Conducting paste 1 tube

Training Aids:

Chart of crimping tool

O.H.P. transparencies of compression connectors , crimping and crimping
pliers
Charts of compression connectors

Procedure:

TASK 1: crimping of lug

1. Collect the cable (multi strand copper conductor)
2. Collect the spade connector suitable to the wire thickness and terminal size
(6mm dia)
3. Select the wire stripper blade size to match the wire thickness or adjust the
jaws of the stripper.(fig 4)
4. Strip off a length of insulation that suits the terminal size( spade
connector).(fig 5)
5. Twist the strands of the wire lighty in the direction of strands(fig6)
6. Select the crimping pliers that matches with the terminal size
7. Clamp the spade connector with the crimping pliers in the matching position
of jaws
8. Insert the wire far enough in the lug( fig 7)
9. Apply light pressure to create a light impression on the lug
10.Check whether the press is located in the middle of the band of lug and, if
necessary ,make final adjustment
11.Apply sufficient pressure in the handle to press the lug fully, as shown in fig
12
12.Check whether the prepared lug joint is firm by pulling the cable
13.Repeat the crimping of lug for various sizes of copper and aluminium
conductors of different lengths