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

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Check crimped connections for correct forming and filling (cross-section, ensure that leads are enclosed correctly).
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 Crimped Connections For Correct Forming And Filling
Courtesy of MERCEDES-BENZ USA

2a Check crimped connection without single-strand insulation (ensure that all lines 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.

Fig 2: Identifying Crimped Connection Without Single-Strand Insulation
Courtesy of MERCEDES-BENZ USA
2b Check crimped connection with single-strand insulation (ensure that all lines are enclosed correctly).
Insulation and single-strand insulation must be positioned in the center and enclosed completely by the crimp tab and they must be able to take up tensile force.

Single-strand insulation must not be pinched otherwise contact corrosion can occur if the connection is penetrated by water.

Correct crimped connection (A):

Wire strands are enclosed correctly by the shackle. Insulation and single-strand insulation are enclosed correctly by the large tab. All parts can withstand the required tensile force.

Incorrect crimped connections (B, C):

The single-strand insulation is not enclosed by the shackle because it was inserted incorrectly during the crimping procedure.

The crimped area of the single-strand insulation is damaged because the wrong die set or wrong single-strand insulation was used.

Fig 3: Identifying Crimped Connection With Single-Strand Insulation
Courtesy of MERCEDES-BENZ USA
3a Check crimped connection without single-strand insulation (ensure that leads and insulation are of 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.

Fig 4: Identifying Crimped Connection Without Single-Strand Insulation
Courtesy of MERCEDES-BENZ USA
3b Check crimped connection with single-strand insulation (for correct length and distance of leads and insulation, as well as position and condition of seal).
Correct crimped connection (A):

Insulation and wires are of the correct length in the shackles. Correct distance between the single-strand insulation and the end of the insulation.

Incorrect crimped connections (B, C):

The single-strand insulation is damaged because the distance between seal and end of insulation is too small.

Stripped strands are too long, single-strand insulation is therefore not crimped.

Fig 5: Identifying Crimped Connection With Single-Strand Insulation
Courtesy of MERCEDES-BENZ USA