0.5 60° A B C D CB2 CH2 CB1 CH1 UNCRIMPED TERMINAL AND WIRE POSITION SETUP FRONT COVER CRIMP CONDUCTOR CRIMP VISUAL INSPECTION VISUAL INSPECTION VISUAL INSPECTION VISUAL INSPECTION INSULATION CRIMP FRONT COVER CRIMP CROSS SECTIONS CRIMPER SIDE CRIMPER SIDE CRIMPER SIDE ANVIL SIDE Incorrect Crimp Quality Good Crimp Quality Test Training TE APPLICATION TOOLING: LITEALUM CRIMP QUALITY GUIDELINES Correct Incorrect Test Training Crimp heights and tolerances Insulation fixation according to application specification 114-94204 For crimp height tolerances for any given contact, please refer to the relevant application specification. Bending test according to application specification 114-94204 Digital crimp height micrometer (0.001 mm increments) according to DIN ISO 9001 Part number: 547203-1 CB2m: Insulation crimp width CB1m: Conductor crimp width CH2: Insulation crimp height CH1: Conductor crimp height Examples Contact Order-No P/N Wire Range Conductor CH1 Insulation CH2 JPT LITEALUM 2-2177894-1 2.5 mm2 ±0.04 mm ±0.1 mm SPT LITEALUM 2-1862001-1 4.0 mm2 ±0.04 mm ±0.1 mm AMP MCP 6.3/4.8K LITEALUM 2-2177840-1 6.0 mm2 ±0.04 mm ±0.1 mm Training schedule information in English or German: Telephone: +49 6151 607 1518 E-mail: [email protected] or contact your local TE Connectivity representative for information in your language. CRIMP HEIGHT MEASUREMENT AND TOLERANCES INSULATION FIXATION TRAINING In the event of large imper- fections, as shown here, the position of the sectioning layer should be checked. Terminal asymmetrically positioned over the anvil Terminal asymmetrically positioned over the anvil Cracking in the bottom of the front cover crimp Axial misalignment of crimp flanks Cover crimp flanks are visible outside crimp Asymmetrical imprint Conductors are visible outside crimp Locking lance Insulation barrel with grips Filler deposit Carrier strip Front cover wings Transition zone Conductor crimp barrel with serrations, covered with additive Terminal body Uniform shape along length, entire seam closed, funnel- shaped expansion between wire and insulation crimps. Seam is closed and no insulation is seen in the seam. A: Front cover crimp B: Wire crimp C: Insulation crimp D: Longitudinal section 110° 110° Wire tip position setup is important to proper termination. Refer to appropriate application specification for instructions. After setup, verify with longitudinal cross section. CH1 CB1m CH2 CB2m Stripping length Front strands flush with reference line 3x 1 1 2 2 3 3 4 4 5 5 6 6 7 7 AMP MCP, LITEALUM, TE Connectivity and TE connectivity (logo) are trademarks. © 2015 TE Connectivity. All rights reserved. The above images of crimp failures are only shown as examples and are by no means exhaustive of all possible failures. In every case, relevant product and application specification take precedence. Where specified by TE Connectivity, Automotive users within EMEA have to meet TE Application Specification 114-94204 when processing open crimp barrels. www.tooling.te.com 1-1654337-5 Revised 04-2015 Housing Filler deposit Crimp barrel Front cover crimp may have different crimp height than wire crimp. Refer to applica- tion specification. Anvil side footprint is symmetrical. Clear anvil impression on both sides of insulation crimp.