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Question

Difficulty: MediumWire Preparation Tools

An electronics technician is preparing a piece of stranded 18 AWG copper hookup wire to attach an insulated crimp terminal. What is the correct chronological sequence of steps the technician should follow using standard wire preparation tools?

  1. 1Cut the stranded wire to the required length using diagonal cutting pliers.
  2. 2Strip the insulation to the specified terminal depth using the correct stranded wire notch on a multi-gauge wire stripper.
  3. 3Inspect the exposed conductor for nicked strands and twist the loose strands tightly together.
  4. 4Insert the bare conductor fully into the terminal barrel and compress it with the matching die of a crimping tool.
  5. 5Perform a gentle pull test to verify that the terminal is firmly seated and mechanically secure.

Answer

Cut wire with diagonal cutters → Strip insulation with calibrated wire stripper → Inspect and twist bare strands → Crimp terminal barrel with crimper → Perform mechanical pull test
The proper sequence follows standard electrical assembly protocol: cutting the conductor to length with diagonal cutters, removing insulation using a properly matched wire stripper notch, inspecting and twisting exposed stranded conductors, seating and compressing the terminal barrel with a crimper, and concluding with a physical pull test to verify mechanical integrity.

Step-by-Step Solution

1
Cut the conductor to length using diagonal cutters (dikes).
Clean cut at the desired total wire length.
Establishing the proper harness length must precede all end-preparation tasks.
2
Select the correct AWG stranded gauge notch on a wire stripper and remove the outer insulation jacket to the manufacturer's recommended strip length.
Cleanly exposed bare conductor strands without severed or nicked wire strands.
Using the matching gauge notch cuts through the insulation without cutting into the metal conductor.
3
Inspect the bare wire strands for any damage and twist the strands clockwise.
A compact, cohesive stranded bundle ready for insertion.
Twisting prevents stray strands from catching outside the barrel and creating a short circuit or high-resistance connection.
4
Seat the stripped conductor into the barrel of the crimp terminal and compress the joint using the appropriate color-coded or sized crimper jaw.
Cold-welded, mechanically deformed gas-tight crimp connection.
The crimping tool applies precise pressure to bond the terminal barrel to the conductor.
5
Gently pull the wire and terminal in opposing directions.
Verification that the wire does not slip out under tension.
A pull test confirms that the crimp has sufficient mechanical retention before placing the wire into service.

Key Concept

Standard wire preparation, stripping, and crimp termination procedure
Estimated Time:1m 0s
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Topics

Wire Preparation Tools

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