Industrial Crimp Quality Handbook
Doc No: TM-640160065
Release Date: 00-00-02
UNCONTROLLED COPY
Page 16 of 27
Revision: C
Revision Date: 12-23-09
Wire within
Outside Diameter
Exceeds
Outside Diameter
Loose Wire
Expanded Strands
ACCEPT
REJECT
Improper Stripping
“Nicked” Strands
Improper Stripping
Cut Strands
Proper Stripping
Undamaged
Strands
ACCEPT
REJECT
ACCEPT
Damage Less
Than 1/2 of
Insulation Thickness
Damage 1/2 of
Insulation Thickness
or Greater
Burred or Charred
Cut
Split
Insulation
Whiskers
REJECT
Insulation
Thickness
SECTION 6
PROCEDURES
6.1
Preparing the Wire
Check the stranded wire to see if any strands have
loosened and expanded to be larger than the wire and
the insulation together. If this has occurred, twist the
wires to the size they were before they were stripped. Be
sure that the stranded wire is within the outside diameter
of the insulation after you have twisted them.
Check the insulation to ensure that there has been
a nice clean cut. Wires with damaged insulation
should not be used.
Check to see if the stripping tool or machine has cut or
nicked any of the wires. If you see nicked wire you must
cut and re-strip the wire before crimping to be sure that
the amount of current that can be carried is not reduced.
6.2
Setup and Operation of a Press
1.
Check that tooling is clean and not worn. If
necessary, clean and replace worn tooling.
2.
Disconnect power to the press and remove
guarding devices.
3.
Install the appropriate tooling into the press.
4.
Load terminals into the tooling so that the first
terminal is located over the anvil.
5.
Manually cycle the press to help ensure a complete
cycle can be made without interference. If it
cannot, remove tooling and check press shut
height. Go to procedure 3.
6.
Check that the tooling is aligned. Check the
impression on the bottom of the crimp that was
made by the anvil tooling. Check that the
extrusions and crimp form are centered. If not,
align tooling and go to
procedure 5.
7.
Check that the terminal
feed locates the next
terminal over the center
of the anvil tooling. If
not, adjust terminal
feed and the feed finger
and go to procedure 5.
8.
Re-install all safety
devices that were removed during the set-up.
(Follow all safety requirements listed in
individual press and/or tooling manuals.)
9.
Crimp sample terminals under power.
10.
Evaluate cut-off tab length and conductor bell
mouth. If adjustment is necessary, disconnect
power to the press and remove guarding. Adjust
