Quality Crimp Handbook
Order No 63800-0029
Release Date:09-04-03
UNCONTROLLED COPY
Page 18 of 24
Revision: B
Revision Date: 10-07-05
Figure 9-10
INSULATION UNDER CONDUCTOR
CRIMP, GOOD CONDUCTOR BRUSH
Figure 9-11
INSULATION UNDER CONDUCTOR CRIMP,
CONDUCTOR BRUSH TOO LONG
Figure 9-12
INSULATION UNDER CONDUCTOR CRIMP,
SHORT OR NO CONDUCTOR BRUSH
Figure 9-13
CONDUCTOR BRUSH TOO LONG
Figure 9-14
CONDUCTOR BRUSH TOO SHORT
Figure 9-15
INSULATION UNDER INSULATION CRIMP,
CONDUCTOR BRUSH TOO LONG
Figure 9-16
INSULATION UNDER INSULATION CRIMP,
CONDUCTOR BRUSH TOO SHORT
Conductor Brush and Insulation Position
Insulation Crimp
Symptom
Cause
Solution
Tighten insulation crimp height
Terminal surrounds less than 88% of a large
diameter wire (Figure 9-21)
Crimp too loose, not enough
terminal insulation barrel
Evaluate terminal
Terminal contacts less than 50% of a small
diameter wire (Figure 9-22)
Too much terminal insulation barrel
Evaluate terminal
Insulation crimp barrels cut through insulation
into conductor strands (Figure 9-23)
Crimp too tight
Adjust insulation crimp height*
Insulation not firmly gripping insulation,
fails bend test (Figure 9-24)
Crimp too loose
Adjust insulation crimp height tighter
* Inexpensive hand tools provide no adjustment for the insulation crimp. A hand tool is intended for low volume applications. Although
you are not able to adjust the insulation crimp on a hand tool, an insulation crimp, which pierces the insulation, may still be
considered acceptable for many applications. This criterion only applies to hand tools due to their low speed crimp cycle. If the
insulation crimp pierces the insulation, the wire strands tend to move aside without damage.
