Examples of Incorrect Crimping

Examples of incorrect crimping


Caution! The most common reason for poor crimp results is using the wrong crimp tool/crimp tool insert for the cable terminal or the wrong area on the matching cable terminal/cable.

Core too large for the core wings




The illustration shows the cross section of the core crimp. The core wings are too small to completely cover the core of stripped copper strands.

Core is too small for the core wings




The illustration shows the cross section of the core crimp with the core which is too small for the core wings. As a result the core is not firmly held in place by the pressure of the core wings on the copper strands.

Reason

Incorrect crimping as shown above can be caused by:
- Cable terminal is the wrong size for the cable area
- The wrong crimp tool or the wrong forming section in the crimp tool was used.

Incorrect location of cable/cable terminal

The stripped cable is not located correctly




The cable has not been pushed far enough in.
The entire stripped core must be located within the core crimp.

The stripped core is too short




The cable insulation is too far forward and has caught under the core crimp.

The stripped core is too long




The insulation is not fully located in the insulation wings.

The stripped core is too long




The stripped core is too far forward past the core crimp.

The stripped core is incorrectly crimped




The strip section is the right length but one of the copper strands is outside the terminal, indicating the terminal was incorrectly located in the crimp tool forming jaws.
All of the strands must be pressed together within the core wings.

Reason

Incorrect crimping as shown above can be caused by:
- Stripping the cable too short or too long.
- Incorrect location in the cable terminal.
- The cable terminal was incorrectly located in the crimp tool forming section.