The wrong crimp tool

[bernardgreen]

Found this when fault finding a battery charger. There was 13.8 volts on the charger terminals and 11 volts on the battery terminals. The brown lead was found to be open circuit but where ?.

The crimp tool used to fold the insulation grip was "one that did the job" but not the one specific to the blade.

( Insulation was removed to gain access for test probes ).

 

[ericmark]

For insulated terminals you need ratchet crimp pliers, however I found the Durite non ratchet were better as you could see they were in the correct place, the ratchet type too easy to not get the cable are crimp slightly out. However not found any other make which do a reasonable job.

 

[Lectrician]

There are proper crimp tools for these terminals. Not your red/blue/yellow type.

 

[mattylad]

That would appear to have been done with the correct type of tool as it has folded over the tabs however the wrong size may have been used or it has been badly done.
Red/Blue/Yellow crimpers do not fold the tabs over like that.

 

[plugwash]

Yeah, it's unfortunate that connector manufacturers charge hundreds of pounds a go for crimp tools. So people make-do with an existing tool that wasn't really designed for the connector in question.

 

[EFLImpudence]

That type don't cost much.

http://www.altecautomotive.co.uk/pr...for-uninsulated-terminals-bralttt71-868-p.asp

 

[mikeyd]

Found this when fault finding a battery charger. There was 13.8 volts on the charger terminals and 11 volts on the battery terminals. The brown lead was found to be open circuit but where ?.

Just a guess, but in my humble opinion; Was the spade (metal bit) fully in the plastic bit to begin with? There is usually what I'd call a tang which should be at least a little bit bent if you've just pulled it out.

 

[Sureitsoff?]

i have these for crimping non insulated terminals like the op, they fold the "ears" over perfectly


https://www.google.co.uk/url?sa=i&r...aw3NeVrCX-YlXSzYQ26xHnqk&ust=1509133578543040

 

[mattylad]

They may do however require 2 actions, crimp once for the insulation tangs and then again on the actual wire.
I prefer the type that do it all in one, are spring loaded with a ratchet, much easier when you have hundreds of this type of connection to do (as they would have had when making the above lead up at the manufacturer).

However, it is easy to "feck it up" by not giving a tsos about what your doing because your paid peanuts and then just letting it be sent out instead of cutting, stripping and redoing it.
Also the tool that did it may have been pneumatic, with those it is extremely easy to damage the wire by not fitting it into the tool correctly.

 

[bernardgreen]

A bit of investigation. It was a hand tool, not ratchet tool. The tool did not have a crimp jaw for the insulation so the largest of the wire crimp jaws were used for crimpong onto the insulation. It would appear the operator used the wrong jaw when doing this failed connector.