• When the wire is in the terminal lug, the end of the conductor extends farther than the end
of the crimp barrel
• The maximum distance from the end of the wire insulation of a single wire to the end of the
crimp barrel is 0.12 inch for AWG 10 and smaller, and 0.25 inch for AWG 8 and larger
• The conductor does not have nicked or cut strands
• If the insulation is removed by the application of heat, the conductor has not moved from the
center of the wire
• If the insulation is removed by the application of heat, the remaining insulation does not
have blisters or evidence of overheating
• The remaining insulation is not frayed.
(5) Put the conductor of the wire in the crimp barrel of the terminal lug.
Make sure that:
• All of the strands of the conductor are in the crimp barrel
• The end of the conductor extends farther than the end of the crimp barrel
• The maximum distance from the end of the wire insulation of a single wire to the end of the
crimp barrel is 0.12 inch for AWG 10 and smaller, and 0.25 inch for AWG 8 and larger.
(6) Crimp the terminal lug.
Make sure that:
• All of the strands of the conductor are in the crimp barrel
• The end of the conductor extends farther than the end of the crimp barrel
• The maximum distance from the end of the wire insulation of a single wire to the end of the
crimp barrel is 0.12 inch for AWG 10 and smaller, and 0.25 inch for AWG 8 and larger.
(7) If the crimp tool is a hex type tool and Table 12 gives a secondary die, crimp the terminal lug
again with the secondary die:
NOTE: The second crimp removes the flash that is made by the first crimp.
NOTE: The removal of the plating from the terminal lug caused by the second crimp is permitted.
(a) Put the secondary die in the crimp tool.
(b) Turn the terminal lug one flat, approximately 60 degrees.
(c) Crimp the terminal lug again.
Make sure that the second crimp is in the same location along crimp barrel as the first
crimp.
ASSEMBLY OF INSULATED AND UNINSULATED TERMINAL LUGS
707, 727-787
STANDARD WIRING PRACTICES MANUAL
20-30-11
Page 78
Oct 15/2017D6-54446
ECCN 9E991 BOEING PROPRIETARY - See title page for details
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