Notes On Crimping - AH00.19-P-1000-09A

Model all (4xWD, CAR, Light transporter, smart) 

1. Check crimped connections for correct forming and filling (cross-section, ensure 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 

   Courtesy of MERCEDES-BENZ USA

2. 1. Check crimped connection without single-strand insulation (ensure line is 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.

      Courtesy of MERCEDES-BENZ USA

   2. Check crimped connection with single-strand insulation (ensure line is 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,

      as otherwise water ingress can cause contact corrosion.

      Correct crimped connection (A): 

      Wire strands are enclosed correctly by the shackle. Insulation and single-strand insulation are enclosed correctly by the large shackle. 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.

      Courtesy of MERCEDES-BENZ USA

3. 1. Check crimped connection without single-strand insulation (ensure 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.

      Courtesy of MERCEDES-BENZ USA

   2. Check crimped connection with single-strand insulation (check 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.

      Courtesy of MERCEDES-BENZ USA