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Cables coming loose from terminal

post #1 of 24
Thread Starter 
I've just started doing my first crimps, but I can't seem to get a good, solid connection between the terminal and wire. If I put the terminal in a connector after crimping it, all it takes is a tug on the wire and the wire comes loose from the terminal. This even happens with crimps that appear good. My cheap power supply I got from a pre-built computer on the other hand does just fine. I can yank on its wires and none of them will come loose from the terminal. The fins holding the stripped part of the wire also look tighter compared to my crimps. Is there some secret to getting a good connection?
post #2 of 24
I had that problem when I first started making crimps until I figured out I was putting the pins in the crimper backwards. The wings (fins) of the pin are supposed to point into the groove of the crimper instead of pointing out.
     
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post #3 of 24
Thread Starter 
I've been following Lutro0's crimping guide on YouTube, so I've been putting the pins in the right way. Going by this drawing, the large wings at cross section H look like they're making a good bite into the insulation, but the wings at cross section G aren't getting as tight a hold on the bare wire as the crimps my purchased PSU came with. I'm using 16 gauge wire if it matters.

The wires require a bit of a pull to get them to come loose, but it's nowhere near as good of a crimp as the ones on my PSU are.
Edited by abbb - 10/24/15 at 9:18am
post #4 of 24
Ok, let me ask some questions:

1. What size wire are you using and what kind of insulation does it have?
2. What kind of crimpers are you using?
3. What kind of pins are you using?
     
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post #5 of 24
Thread Starter 
I got everything from MainFrame Customs.

1. MFC Custom 16 Gauge wire
2. LC Ratchet Crimper
3. Just the standard Female ATX ones.
post #6 of 24
You may be doing something wrong, then. Watch the video again and pay close attention to which way the crimper and pin are oriented when making the final crimp. Since you are making two crimps—one on the wire and one on the insulation—at the same time, if you have the pin inserted in the wrong direction, you would be making the crimp on the wire too loose and the insulation crimp tight enough to cut into the insulation and weaken it. If that isn't the case, you may need to readjust the little adjustment wheel up a notch to make tighter crimps.
     
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post #7 of 24
i had that problem , but it was because i was using chinese terminals

can you show pictures?

are you using the crimping tool to the last click sound and then some for the automatic release? (that is what i do , i guess its because i use awg18 wire)
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post #8 of 24
Typically if your having the wire pull out of the terminal you have a possibility of four issues:

1) Strand damage from stripping the wire insulation
2) Crimp is too tight (strands are being severed, wire/terminal gauge combination)
3.) Crimp is too loose (wrong guage setting, or wrong wire/terminal combination)
4) Terminal positioning in tool leads to no bellmouth at wire crimp entry (damages strands)


These are not all inclusive, there could be other issues at play here such as defective tooling. I noticed that you purchased a 16AWG wire, however the tool you are using is rated for either 18-22AWG or 24-30AWG wire. The terminal you are using is more than likely for the 18-22AWG wire. Using a 16AWG wire in this configuration could cause some of the strands to become fractured, and reduce the quality of the connection, although the wire shouldn't pull out unless the strands are completely severed.

I work at a wire harness manufacturing facility and specialize in wire crimps among other things related to the manufacture of wire harnesses. If you post some pictures of the crimps you are making, I would have a better idea of what is going on here.
post #9 of 24
Quote:
Originally Posted by Mattb2e View Post

Typically if your having the wire pull out of the terminal you have a possibility of four issues:

1) Strand damage from stripping the wire insulation
2) Crimp is too tight (strands are being severed, wire/terminal gauge combination)
3.) Crimp is too loose (wrong guage setting, or wrong wire/terminal combination)
4) Terminal positioning in tool leads to no bellmouth at wire crimp entry (damages strands)


These are not all inclusive, there could be other issues at play here such as defective tooling. I noticed that you purchased a 16AWG wire, however the tool you are using is rated for either 18-22AWG or 24-30AWG wire. The terminal you are using is more than likely for the 18-22AWG wire. Using a 16AWG wire in this configuration could cause some of the strands to become fractured, and reduce the quality of the connection, although the wire shouldn't pull out unless the strands are completely severed.

I work at a wire harness manufacturing facility and specialize in wire crimps among other things related to the manufacture of wire harnesses. If you post some pictures of the crimps you are making, I would have a better idea of what is going on here.

The tool the OP is using has been modified by the vendor to handle #16 wire. The pins come from the same vendor and are designed to handle the wire. Also, he is using wire from the same vendor which has considerably thinner insulation (I have the same wire and it's amazing how much thinner it is). In this video, the vendor explains all this and demonstrates doing the crimps with the #16 wire.

I have crimped up to two #14 wires to a four pin female Molex power pin but I used a different crimper and pins that had longer wings (those are a wee bit hard to find). The crimper was an el cheapo that crimped the wire and the insulation wings separately. 'Twas a bit fiddly to do, however, especially since I was doing it while the cable was still inside the computer (I needed to add a second four pin power connector to the end of a cable in a rather cramped case and it would have taken hours to R&R the cable instead of the 30 minutes it took to do the job in place).



Edited by Lady Fitzgerald - 10/25/15 at 12:11am
     
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post #10 of 24
Quote:
Originally Posted by Lady Fitzgerald View Post

The tool the OP is using has been modified by the vendor to handle #16 wire. The pins come from the same vendor and are designed to handle the wire. Also, he is using wire from the same vendor which has considerably thinner insulation (I have the same wire and it's amazing how much thinner it is). In this video, the vendor explains all this and demonstrates doing the crimps with the #16 wire.

I have crimped up to two #14 wires to a four pin female Molex power pin but I used a different crimper and pins that had longer wings (those are a wee bit hard to find). The crimper was an el cheapo that crimped the wire and the insulation wings separately. 'Twas a bit fiddly to do, however, especially since I was doing it while the cable was still inside the computer (I needed to add a second four pin power connector to the end of a cable in a rather cramped case and it would have taken hours to R&R the cable instead of the 30 minutes it took to do the job in place). Warning: Spoiler! (Click to show)


I'm not saying that it cannot be done, you will just not have the same quality with using oversized wires in a terminal that is not designed to handle it. The CMA of the wire must meet the CMA range of the terminal in order to make a quality gas tight connection. This is not to say that failure to follow this will preclude a usable crimp, as it will indeed still function. It will just not be as reliable as a crimp using the appropriate tooling and materials. You say the terminal will accept up to 16AWG wire, so if this true there should be no sizing issues. Looking at the Molex part for this application (assuming we are talking about the same terminal here), they are designed for 14-20AWG wire, which tells me that this is not a gauge mismatch issue.

I have still not seen the photos from the OP, so it is hard to tell what is going on here without seeing first hand. It could just be as simple as improper strip length, or misalignment in the tool. Additionally, if he is crimping wire insulation in the conductor crimp, it will cause the failure that the OP is seeing.
Edited by Mattb2e - 10/25/15 at 11:55am
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