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Quality Crimp Handbook
Insulation Crimp
Symptom
Terminal surrounds less than 88% of a large
diameter wire (Figure 9-21)
Terminal contacts less than 50% of a small
diameter wire (Figure 9-22)
Insulation crimp barrels cut through insulation
into conductor strands (Figure 9-23)
Insulation not firmly gripping insulation,
fails bend test (Figure 9-24)
Cause
Crimp too loose, not enough
terminal insulation barrel
Too much terminal insulation barrel
Crimp too tight
Crimp too loose
Solution
Tighten insulation crimp height
Evaluate terminal
Evaluate terminal
Adjust insulation crimp height*
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.
Figure 9-17
PREFFERRED
INSULATION CRIMP
Figure 9-18
PREFFERRED
INSULATION CRIMP
Figure 9-19
ACCEPTABLE
INSULATION CRIMP
Figure 9-20
ACCEPTABLE INSULATION CRIMP
Figure 9-21
MARGINAL INSULATION CRIMP
Figure 9-22
MARGINAL INSULATION CRIMP
Figure 9-23
MARGINAL INSULATION CRIMP
Figure 9-24
MARGINAL INSULATION CRIMP
Order No: TM-638000029
Revision: D
Release Date: 09-04-03
Revision Date: 12-23-09
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