CRIMPING GUIDELINES

CORRECT CRIMP INCORRECT CRIMP TEST

Wire barrel too tight Wire inserted at the back Terminal bend up or down
Conductor present Locking lance and
terminal body
Bellmouth must Wire Crimp
always be present
not deformed

Reason of error : Incorrect cable placement.

Reason of error : Flash at the bottom of crimp, due to over crimping. Reason of error : The height of anvil.
Solution : Place cable according to correct crimp sample.
Solution : Correct crimp height setting, check crimper-anvil set. Solution : The heights of the crimper and anvil must be the
same.
Insulation present
Wire barrel too loose Wire inserted too far Carrier cut-off too long or not existent
Bellmouth permissible Peak of the micrometer should lean
Crimp height measurement to the back side of the terminal and
Digital crimp height micrometer smooth part to the top of the
(0.001 mm increments). terminal.
Reason of error : Incorrect cable placement.
Reason of error : Insufficient wire deformation, showing space. Solution : Cable must be placed correctly.

Cut off tabs present

Solution : Correct crimp height setting, check crimper-anvil set.
Insulation Crimp
Strip length too short Undersized bellmouth
Wire crimp without conductor.
Wire Crimp 30o
Correct selection of wire, terminal and applicator. Reason of error : No carrier cut-off puts crimp barrels and terminal
mouth out of action. Cut off has to be as the same
Reason of error : Crimper is damaged, wrongly mounted or incorrect feeding of length as material thickness.
Reason of error : Incorrect cable strip. the terminals. Solution : Check the all crimping tools and pitch of terminal.
Solution : Extend the cable strip length. Solution : Change wire crimper, fix mounting, correct the feeding.
Insulation must be securely
held after bend test. 30o
Crimp barrels are closed, Sufficient gap between Strip length too long Oversized bellmouth
barrels support each barrels and bottom of Terminal twisted
other. crimp. Wire crimp Cutting Remove insulation
with conductor Check the conductors for damage
Insulation Crimp Reason of error : Incorrect cable strip. Reason of error : Crimper is damaged, wrongly mounted or incorrect feeding of
Correct insulation diameter, terminal and applicator. Solution : Lower cable strip length. the terminals.
F Crimp Solution : Change wire crimper, fix mounting, correct the feeding.
Check: Cut off the insulation support and remove the wire insulation, then check the wire conductors for damage.
Wire strands loose Crimp too far forward
Reason of error : Differences between the heights of the crimper
and anvil in the applicator, mounting mistakes,
Required Measurements
Cbm
abrasion or terminal caught during operation.
Solution : Eliminate the reason for twisting. Cb
Insulation is securely held. Hs
Reason of error : Cable strands loose or crimp not completed. Reason of error : Crimper deforms contact area.
Crimp barrels closed. Solution : Cable strands must be collected before crimp and Solution : Check the position of terminal during crimping, check the
Ch
conductor barrels must be adjusted for secure holding. crimpers and anvil.
Bh
The smallest diameter wire should be placed at the bottom for double wire If there are no crimp height tolerances
applications . Terminal twisted Insulation leg distorted Terminal damaged specified in the technical drawing of the
Crack
Supporting height (Hs) must be;
Reason of error : Differences between Reason of error : Differences between Reason of error : Terminal contact terminal, the following tolerances are valid Bw
Overlap the heights of the crimper and anvil in
the applicator, mounting mistakes,
the heights of the crimper and anvil in
the applicator, mounting mistakes,
area damaged, no cut off. regarding the crimp height (Ch): Burr height (Bh) must be less than or equal to
the contact material thickness (S).
Crimp abrasion or terminal caught during
operation.
abrasion or terminal caught during
operation. Bh ≤ 1.0 x S
Burr width (Bw), must be less than or equal to
½ of the contact material thickness (S).
Crimp range ( Ch), Crimp width (Cb) (S): Material thickness
Measurable crimp width (Cbm) Bw ≤ 0.5 x S
Insulation is securely held.
Sa
Barrels overlap.
Solution : Check the position of Solution : Check the all crimping tools
X2
X1
terminal during crimping, check the and pitch of the applicator.
Solution : Eliminate the reason for twisting. crimpers and anvil. Fc Cfe

Wrap Overlap Insulation Crimp Wire Crimp Sb

Distance between crimp face ends
Crimp Insulation is pierced and Insulation barrels
Face and clearance (Fc) must
be greater than or equal to
(CFE) must equal the distance Supporting angle (Sa) must
Base thickness (Sb) should
Insulation material Insulation is not securely Insulation is over crimped. between the bottom edges of the not deviate more than 30O
Insulation is securely held. damaged conductor. are not closed. is pierced. held, barrels do not overlap. 1/10 of the contact material rolled crimp barrels. This value must from the vertical axis.
be greater than or equal to
Barrels must pass each other. thickness (S). be less than or equal ½ of the ¾ of the contact material
Sa ≤ 30O
Fc ≥ 0.1 x S contact material thickness (S). thickness (S).
Asymmetric crimp, Sb ≥ 0.75 x S
Wire size too large, Crimp height too loose, CFE = |X1-X2| CFE ≤ 0.5 x S
Other Crimp Samples terminal feed incorrectly
adjusted.
crimp barrels do not close. insufficient deformation,

‘‘W’’ Crimp Confined Crimp Trapezodial Crimp Indent Crimp

Insulation is not securely
showing voids.
Crimp Pull Force Test
held.
Test values for crimp pull force
(According to EN 61210 & EN 60352)
Unacceptable formation Crimp height too tight,
Wire size too small,
excessive burr and/or cracks, burr at underside of
barrels too close to
anvil and crimper crimp.
bottom of crimp.
not aligned or worn out.
Insulation supports
Tab-Lock Crimp Bar Crimp Incorrect Strip should be uncrimped
during the crimp pull
Strands damaged Insulation
Strands are loose and/or cut-off Uneven strands length Uneven insulation cut Pulled strands on the strands
Inconsistent strip length force test.

If two wires are crimped together,

each wire is compared respectively
by its own value in the table .

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