Notes on crimping - AH00.19-P-1000-09A

Model 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 414, 461, 463

Check crimped connection for deformation and ensure that the wires fill the crimp tab correctly (cross-section of enclosed wires).
Correct crimped connection (A):

The strands of the cable are evenly enclosed.

The crimp tab is evenly shaped.

Incorrect crimped connection (B):

The crimp tab has an incorrect cross-section and is not full enough.

Incorrect crimped connection (C):

Individual wire strands are outside the crimp shackle.

The crimp tab is too full.

Incorrect crimped connection (D):

The crimp claws touch the bottom of the crimped fitting.

The crimp tab is too full.

The crimp tab is deformed and therefore damaged.

Shown with circular conductor

Fig 1: Identifying Correct And Incorrect Crimped Connections
Check crimped connection (ensure all wires are enclosed correctly).
Correct crimped connection (A):

Leads (3) enclosed correctly by the tab (2).

Insulation is enclosed correctly by the tab (1).

Incorrect crimped connection (B, C):

Leads (3) are damaged due to deformed tab (2).

Insulation is pinched by deformed tab (1) and damaged.

Shown with circular conductor

Fig 2: Identifying Crimped Connections With Correct And Incorrect Crimped Connections
Check crimped connection (ensure that wires and insulation are correct length).
Correct crimped connection (A):

Correct length of insulation is enclosed by the shackle (1).

Wires (3) are the correct length in the tab (2).

Incorrect crimped connection (B):

Insulation is too short and is not correctly enclosed by the tab (1).

Therefore insulation cannot withstand the required tensile load.

Incorrect crimped connection (C, D):

Wire strands (3) are too long.

Leads (3) are too short.

Shown with circular conductor

Fig 3: Identifying Crimped Connections With Correct And Incorrect Wires And Insulation Length