Datasheet

114- 2157

Rev G 5 of 14

The wire conductor(s) must not be nicked, scraped, or cut dur ing the stripping operation.

3.4. Wire Placement

The stripped wire must be inserted into the wire barrel until the wire insulation is against the wire barrel but not

inside it. The wire insulation must be inside the metal sleeve. A gap between the wire insulation and wire barrel

is allowed, but not to exceed the dimension given in Figure 3.

Figure 3

Wire Barrel

Wire Insulation May Butt Against,

But Not Enter, Wire Barrel

1.59 [.062]

Maximum Gap

Wire Insulation Must Be

Inside Metal Sleeve

Splice

Insulation

Transparent Insulation Window Butt Splice Shown

Metal Sleeve

3.5. Crimp Requirements

A. Crimp Height

The spring--back of the terminal, splice, or end cap insulation prevents an accurate direct measurement of

crimp height. However , crimping a slug of solder (60% tin and 40% lead) with a diameter slightly larger

than the conductor outside diameter can verify proper termination. The crimp height of the resulting solder

slug can be checked with a standard micrometer or comparator. The measurement must be made over

the most compressed area of the solder slug. See Figure 4.

Some tooling with multiple crimping chambers form an embossed dot code in the terminal, splice, or end cap

insulation that indicates which crimping chamber was used. This dot code can be used as a visual inspection to ensure

that the correct wire size and crimping chamber were used.

The resilience of the splice insulation prevents accurate direct measurement of crimp height. Crimp height can be

obtained by measuring a crimped solder slug (60% tin and 40% lead) with a diameter comparable to the wire size.

The slug must be measured over the most compressed area of the slug with a standard micrometer or crimp height

comparator (refer to 408--7424 for specific instructions). The solder slug diameter and crimp height must be within the

dimensions provided in Figure 4.

B. Wire Barrel Crimp Profile and Location

The wire barrel crimp produced by the tooling (dies, heads, hand tools, pneumatic tools, or machines)

must be either a confined crescent crimp which appears as a depressed oval shape or a flat rectangular

crimp over the center of the wire barrel. The crimp must be evenly formed. Refer to Figures 4, 5, and 11.

Crescent crimp tooling produces the crescent crimp, and TETRA--CRIMP tooling produces the flat

rectangular crimp. For a tooling--to--crimp profile cross--reference, refer to Figure 10.

C. Dot Code

The dot code on the insulation must be well formed and correspond with the wire size or color code

marking on the crimping chamber of the tooling used. See Figures 4 and 5.

D. Bellmouths

There shall be no rear bellmouth. The front bellmouth shall be evident on the top and bottom of the wire

barrel as shown in Figure 5. Also see Figure 11.

NOTE