Introduction
This manual provides instructions for the safe and effective use of the Dorman 85596 Electrical Wire Stripper/Crimper. This self-adjusting tool is designed to create clean, professional-looking electrical connections by stripping wires and crimping terminals without the need for solder. It is suitable for a variety of wire types and sizes, offering a permanent, reliable connection for electrical repairs and accessory installations.
Safety Information
Always observe the following safety precautions when using this tool:
- Wear appropriate personal protective equipment, including safety glasses, to protect against flying debris.
- Ensure the power source is disconnected before working on electrical wires to prevent electric shock.
- Keep hands and fingers clear of the cutting and crimping jaws during operation.
- Do not use the tool for purposes other than wire stripping, crimping, or cutting.
- Inspect the tool for damage before each use. Do not use a damaged tool.
- Store the tool in a dry, secure place, out of reach of children.
Product Overview
The Dorman 85596 is a versatile hand tool designed for electrical work. It combines the functions of a wire stripper, crimper, and cutter into one self-adjusting unit.
Image: Dorman 85596 Electrical Wire Stripper/Crimper. This image displays the tool with its yellow handles and black metal body, showing the stripping and crimping jaws.
Key Features:
- Self-Adjusting Stripping Jaws: Automatically adapts to various wire gauges for precise insulation removal.
- Crimping Jaws: Designed for secure, solderless crimping of electrical terminals.
- Wire Cutter: Integrated cutting function for clean wire preparation.
- Ergonomic Handles: Plastic handles provide a comfortable and secure grip.
Setup
The Dorman 85596 Wire Stripper/Crimper is ready for use directly out of the packaging. No assembly is required.
- Inspection: Before first use, inspect the tool for any signs of damage or manufacturing defects. Ensure the jaws open and close smoothly.
- Familiarization: Familiarize yourself with the different parts of the tool: the stripping jaws, crimping sections, and wire cutter.
Operating Instructions
1. Wire Stripping
- Prepare the Wire: Ensure the wire is clean and free from kinks.
- Insert Wire: Open the tool handles and insert the end of the wire into the self-adjusting stripping jaws. Position the wire so that the desired length of insulation to be removed is within the jaws.
- Squeeze Handles: Firmly squeeze the handles together. The jaws will automatically grip the insulation, cut it, and pull it away from the conductor.
- Release: Release the handles to free the stripped wire.
- Note: For very fine or very tough insulation, a slight rotation of the tool around the wire before pulling may assist in cleaner stripping.
2. Wire Crimping
The tool features dedicated sections for crimping insulated and non-insulated terminals.
- Select Terminal: Choose the appropriate terminal for your wire gauge and application.
- Insert Terminal: Place the terminal into the corresponding crimping section of the tool. Ensure the terminal is seated correctly.
- Insert Wire: Insert the stripped end of the wire into the terminal.
- Crimp: Squeeze the handles firmly and completely until the crimp mechanism releases or the handles are fully closed. This ensures a secure, permanent connection.
- Inspect: After crimping, gently tug on the wire to ensure the terminal is securely attached.
3. Wire Cutting
Use the designated wire cutter section of the tool for clean cuts.
- Position Wire: Place the wire into the cutting jaws.
- Cut: Squeeze the handles firmly to cut the wire.
Maintenance
- Cleaning: After each use, wipe the tool clean with a dry cloth to remove any wire fragments, insulation residue, or dirt.
- Lubrication: Periodically apply a light machine oil to the pivot points and moving parts to ensure smooth operation and prevent rust.
- Storage: Store the tool in a dry environment to prevent corrosion. Keep the jaws closed when not in use to protect them.
- Inspection: Regularly check the jaws for wear or damage. Replace the tool if the jaws are chipped, bent, or no longer provide a secure grip.
Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Wire not stripping cleanly or insulation is partially cut. | Wire not fully inserted; dull jaws; incorrect wire type for tool. | Ensure wire is fully inserted. Rotate tool slightly during stripping. Inspect jaws for wear; replace tool if necessary. |
| Wire conductor is nicked or cut during stripping. | Jaws are too tight (unlikely with self-adjusting); improper technique. | Ensure the wire is centered. If problem persists, the tool may be faulty. |
| Terminal not crimping securely. | Incorrect crimping section used; handles not fully squeezed; wrong terminal size. | Use the correct crimping section for the terminal type. Squeeze handles completely. Ensure terminal matches wire gauge. |
| Tool feels stiff or difficult to operate. | Lack of lubrication; dirt or debris in mechanism. | Clean the tool and apply a light machine oil to pivot points. |
Specifications
- Model Number: 85596
- Brand: Dorman
- Item Type Name: Electrical Wire Stripper/Crimper Self-Adjusting
- Color: Black, Yellow
- Item Weight: 11.2 ounces
- Handle Material: Plastic
- Grip Type: Ergonomic
- Included Components: 1 Self-Adj Wire Strip
- Specific Uses: Electrical repair and installation, DIY projects
Warranty Information
The Dorman 85596 Electrical Wire Stripper/Crimper comes with a Limited Lifetime Warranty from the manufacturer. For specific details regarding warranty coverage, terms, and conditions, please refer to the official Dorman warranty documentation or contact Dorman customer support.
Customer Support
If you have any questions, require assistance, or need to report an issue with your Dorman 85596 Electrical Wire Stripper/Crimper, please contact Dorman customer support. You can typically find contact information on the official Dorman website or through the retailer where the product was purchased.
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