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Cables coming loose from terminal - Page 2

post #11 of 24
Thread Starter 
Most of the crimps I've done look something like this: Warning: Spoiler! (Click to show)



From what I can tell, the wings holding the wire aren't tight enough to keep it in place when you give it a yank.
post #12 of 24
It appears your crimps are not tight enough. I would try readjusting your crimpers to the next highest setting (they are normally set at the lowest setting when received from MainFrame Customs so they can be adjusted only tighter).
     
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post #13 of 24
Thread Starter 
I tried the next highest, middle, and highest settings. They all produced a crimp that looks very similar, and still comes out if you stick it in a connector and give it a tug.

My initial thought was that this 16 gauge is too big, but that's what Lutro0 uses in his Crimping guide.

How much force does it generally take to remove the wire from the terminal while it's in a connector?
post #14 of 24
Quote:
Originally Posted by abbb View Post

I tried the next highest, middle, and highest settings. They all produced a crimp that looks very similar, and still comes out if you stick it in a connector and give it a tug.

My initial thought was that this 16 gauge is too big, but that's what Lutro0 uses in his Crimping guide.

How much force does it generally take to remove the wire from the terminal while it's in a connector?

It takes quite a bit of force. I usually break the wire if the pin is in a connector or damage the pin from gripping it in pliers before I can pull the wire out.

I just ordered some pins and a crimper from MainFrame yesterday (I already have the wire) to replace my el cheapo crimper and should be getting it later this week so I'll give it a try to see what happens.

Edit: I just looked at your photos again and, although it appears you are getting a decent bite on the insulation, the wings on the wire itself are definitely not getting compressed enough. Two more questions:

1. Are you squeezing down on the crimper until it automatically releases the pin or are you using the release lever to release the pin after crimping?

2. Have you tired inserting the pin/wire assembly into the crimper from the other side? Putting them in from the wrong side is the only thing I can think of right now that could cause the wire crimp to be loose while being tight on the insulation
Edited by Lady Fitzgerald - 10/26/15 at 2:30pm
     
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post #15 of 24
Yeah, those conductor crimp tabs are no where near being closed. Are you sure you are using the right terminal for this job? The description leaves much to be desired as it doesn't describe what gauge range this terminal is.
The terminal you need is a Mini Fit Jr. p/n 39-00-0080 . Here is a link to buy some http://www.mouser.com/ProductDetail/Molex/39-00-0080/?qs=EeaHXY5iaaOeOn6lmyPhig%3D%3D

If you have a caliper, you can measure the terminals you have to the spec. sheet and see if what you have matches the 16AWG terminal specifications. http://www.molex.com/pdm_docs/sd/039000080_sd.pdf
Edited by Mattb2e - 10/26/15 at 6:05pm
post #16 of 24
abbb - Your crimps look inconsistent particulalry the wire crimp. The insulation crimp appears to be biting too deep into the insulation.

Are the jaws in the Crimp Tool tightened up fully? They may need adjustment although the pin normally distorts or breaks if they do.

Are you putting the pin in the tool as far as it will go so that the rear wings are butting up against the little 'notch' (where the wire crimp is made) on the tool?

Have you tried pre-crimping the pins? I don't know what diameter the wire is but for thicker wire pre-crimping the pin about 3 clicks should be enough.
Edited by Big Elf - 10/26/15 at 6:30pm
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post #17 of 24
Quote:
Originally Posted by Mattb2e View Post

Yeah, those conductor crimp tabs are no where near being closed. Are you sure you are using the right terminal for this job? The description leaves much to be desired as it doesn't describe what gauge range this terminal is.
The terminal you need is a Mini Fit Jr. p/n 39-00-0080 . Here is a link to buy some http://www.mouser.com/ProductDetail/Molex/39-00-0080/?qs=EeaHXY5iaaOeOn6lmyPhig%3D%3D

If you have a caliper, you can measure the terminals you have to the spec. sheet and see if what you have matches the 16AWG terminal specifications. http://www.molex.com/pdm_docs/sd/039000080_sd.pdf

Again, he got his pins from Mainframe customs so he is using the correct pin. Did you watch the video I linked?

Based on his photos, it appears he may be putting the pin in from the wrong side of the crimper. That would have the narrower part of the jaws on the insulation crimp and the wider part on the conductor which could account for the conductor wings not being crimped as much as the insulation wings.
Edited by Lady Fitzgerald - 10/26/15 at 6:47pm
     
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post #18 of 24
Quote:
Originally Posted by Lady Fitzgerald View Post

Again, he got his pins from Mainframe customs so he is using the correct pin. Did you watch the video I linked?

Based on his photos, it appears he may be putting the pin in from the wrong side of the crimper. That would have the narrower part of the jaws on the insulation crimp and the wider part on the conductor which could account for the conductor wings not being crimped as much as the insulation wings.

I did watch the video, and I have nothing good to say about it, so I will keep to myself. He has mechanically modified the tooling to work with thicker gauge wire, however the contact needs to also support that same gauge range in order for the crimp to be sufficient. 18-20AWG, and 16AWG Mini Fit Jr. sockets look fairly similar, which is why I posted a link to the datasheet. If the OP wants he can verify that what he bought is what he needs. People make mistakes, it wouldn't be out of the realm of possibility that the wrong terminals were shipped to him.

Even with high volume distributors such as DigiKey, Mouser, and Allied Electronics, wrong parts can be sent out. Anytime the human element is involved, there is a possibility of error. I'm not saying that definitively this is the answer, I am just suggesting it as a possibility.
post #19 of 24
Thread Starter 
Quote:
Originally Posted by Lady Fitzgerald View Post

It takes quite a bit of force. I usually break the wire if the pin is in a connector or damage the pin from gripping it in pliers before I can pull the wire out.

I just ordered some pins and a crimper from MainFrame yesterday (I already have the wire) to replace my el cheapo crimper and should be getting it later this week so I'll give it a try to see what happens.

Edit: I just looked at your photos again and, although it appears you are getting a decent bite on the insulation, the wings on the wire itself are definitely not getting compressed enough. Two more questions:

1. Are you squeezing down on the crimper until it automatically releases the pin or are you using the release lever to release the pin after crimping?

2. Have you tired inserting the pin/wire assembly into the crimper from the other side? Putting them in from the wrong side is the only thing I can think of right now that could cause the wire crimp to be loose while being tight on the insulation

1. I'm squeezing all the way until the crimiper automatically releases.
2. When I put the terminal in the crimper, the long wings are flush up against the little ridge on the crimper. The larger wings are in the wider part of the jaws, and the smaller wings in the narrow part.

Unfortunately I don't have a caliper, so I can't check the dimensions of the terminal. I guess the best course of action would be to try a different gauge wire or order some different terminals?
post #20 of 24
Quote:
Originally Posted by abbb View Post

Quote:
Originally Posted by Lady Fitzgerald View Post

It takes quite a bit of force. I usually break the wire if the pin is in a connector or damage the pin from gripping it in pliers before I can pull the wire out.

I just ordered some pins and a crimper from MainFrame yesterday (I already have the wire) to replace my el cheapo crimper and should be getting it later this week so I'll give it a try to see what happens.

Edit: I just looked at your photos again and, although it appears you are getting a decent bite on the insulation, the wings on the wire itself are definitely not getting compressed enough. Two more questions:

1. Are you squeezing down on the crimper until it automatically releases the pin or are you using the release lever to release the pin after crimping?

2. Have you tired inserting the pin/wire assembly into the crimper from the other side? Putting them in from the wrong side is the only thing I can think of right now that could cause the wire crimp to be loose while being tight on the insulation

1. I'm squeezing all the way until the crimiper automatically releases.
2. When I put the terminal in the crimper, the long wings are flush up against the little ridge on the crimper. The larger wings are in the wider part of the jaws, and the smaller wings in the narrow part.

Unfortunately I don't have a caliper, so I can't check the dimensions of the terminal. I guess the best course of action would be to try a different gauge wire or order some different terminals?

I'm tapped out until I get the stuff I ordered and can try it out myself.
     
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