GLOBAL
APPLICATION TOOLING
DIVISION
Quality Guidelines
Tyco Electronics
Crimp Technology
All figures are schematic depictions. In every case, relevant product and application specification take precedence. 1309130–1.5M–TP © 2002 Tyco Electronics AMP GmbH
Correct Incorrect
F-
CR
IM
P
For double wire applications with different size wires
always place wire with smallest outer diameter in the bottom.
Insulation is securely held
Crimp barrel closed
Bellmouth must always be present
Locking lances and terminal body
not deformed
Terminal bend
Conductor Present
Insulation Present
Bellmouth Permissible
Cut off tabs present
Crimp barrel is closed,
legs support each other
Crimp barrel does
not close.
Legs too close to bottom
of crimp. Insufficient
deformation of strands,
showing voids.
Insufficient
deformation,
showing voids
Flash at under side
of crimp,
due to over crimping
Terminal feed
incorrectly adjusted
Anvil and crimper
not aligned or worn
Wire size to large Wire size to small
Wire crimp without conductor
Insulation must be
securely held
after bend test
Crimp height too loose Crimp height too tight
Asymmetric
crimp
Unacceptable formation
excessive flash and/or
cracks
Sufficient gap
between legs
and bottom of crimp
All strands are equally distributed
and deformed
Insulation is pierced and could damage conductor
Insulation material is pierced
Insulation is
over crimped
Insulation legs are not closed
Insulation is not securely held
Legs do not overlap
Insulation is
not securely held
Insulation is securely held
Legs overlap
Insulation securely held
Legs must pass each other
OV
ER
LA
P
CR
IM
P
Correct Insulation Diameter, Applicator and Terminal.
Correct selection of wire,
terminal and applicator
Digital crimp height micrometer
(0.001mm increments) according to DIN ISO 9001
part number 547203-1
Incorrect terminal/wire selection
Incorrect crimp height adjustment
Incorrect applicator adjustment
Crimp height measurement Crimp heights and tolerances
W
RA
P
OV
ER
CR
IM
P
Test
Training
Conductor Brush protruding into terminal body
Bellmouth on wrong end
Insulation inside the wire crimp
Crimp height too tight
Terminal twisted
Terminal damaged
Cut off tab deformed
Cut off tab too long Crimp barrel distorted
WIRE CRIMP
WIRE CRIMP
WIRE CRIMP
INSULATION CRIMP
INSULATION CRIMP
INSULATION CRIMP
30°
30
°
Please contact our service hotline for
current training schedule.
Tel.: ++44 12 37 42 86 73
Fax: ++44 12 37 42 86 89
For crimp height tolerances for any given contact,
please refer to the relevant application specification.
Examples:
Contact P/N Wire Range Tolerance Application Spec.
MQS 962885 0,20 - 0,50 mm2 ± 0,03 mm 114-18025
962886
JPT 927775 0,50 - 1,00 mm2 ± 0,05 mm 114-18050
JPT 927773 1,50 - 2,50 mm2 ± 0,05 mm 114-18050