Ultimate Troubleshooting Guide: Wire Cutting & Crimping Machines – Solve 95% of Common Issues (2025 Edition)
Wire cutting and crimping machines are vital for high-speed, high-accuracy wire harness processing in industries like automotive, appliances, control cabinets, and telecom. However, issues in blade wear, feeding misalignment, or terminal deformation can lead to operational downtime.
🔧 Common Issues & How to Fix Them
Q: Why are wire cutting lengths inconsistent?
- Feeding wheel pressure is low → Tighten the spring tension.
- Wire slipping during feed → Clean feed rollers and adjust tension.
- Blade misalignment → Re-calibrate the cutting blade mechanism.
Q: Wire core damaged during stripping?
- Blade depth too deep → Adjust stripping value on screen.
- Blade edge worn → Inspect and replace with new crimping blade.
- Improper pull-back value → Modify retraction parameters.
Q: Back-end stripping fails – why?
- Jaws too loose → Adjust gripping tension.
- Stripping wheel not centered → Re-calibrate stripping axis.
- Blade cannot complete stroke → Clean blade holder from debris.
Q: Terminal crimping fails or is loose?
- Die position error → Adjust crimping die holder position.
- Insufficient air pressure → Check compressor feed and regulator.
- Mismatch in wire size and terminal → Verify crimp tool specifications.
Q: Motor overload or abnormal vibration?
- Feeding jam or blocked encoder → Inspect roller path.
- Drive belt loose → Re-tighten or replace belt.
- Controller error → Reset or replace PLC card if needed.
📦 Factory Assembly and Packaging Quality
All our wire cutting and crimping machines undergo factory pre-testing, full calibration, and safety checks before packaging. Machines are secured in reinforced wooden crates to ensure damage-free delivery worldwide.
⚙️ Pro Tips to Enhance Performance
- Use high-hardness alloy blades to double the replacement cycle.
- Lubricate feeding gears weekly to prevent motor strain.
- Upgrade to smart PLC models with auto-diagnosis and error code display.
- Check jaw clamping force using a pressure gauge monthly.