Connectors and crimpers - Page 1
Forum section: electronics / beginners

author: rabbithutch
author_rank: Newbie
timestamp: January 16, 2019, 10:50:04 pm
content: I'm a neophyte with electronics despite being in my 8th decade of life. I'm new here; so be gentle, please.I bought a small, bare bones PSU to drive a rust removal electrolysis set up. In making a supply power cord, I chose 14/3 wire for Neutral, Load and Ground. There are 3 lugs for those wires and 4 lugs for outputs on the PSU rated at 12V 10A. I had to buy bare cord and add connectors. I had no problem putting a mains plug on the cord, but have run into problems with connectors for the AC power input.I have a supply of various connectors. The PSU lugs are small screws; so I planned to place the 'ring' type connector on each of the wires - black, white, green - for load, neutral and ground. I chose connectors that fit the lug space that I could put the AWG 14 gauge wire. In trying to crimp connectors on the wire, I managed to lock up a pair of ratcheting crimpers designed to crimp Molex pins. I don't know how to release the crimper. Can anyone help? The crimpers were intended for use with molex pins. I chose these crimpers after being unable to crimp with other simple crimpers. I realize that I used the wrong tool, now.I would greatly appreciate suggestions.rh

author: Gregg
author_rank: Super Contributor
timestamp: January 16, 2019, 11:23:37 pm
content: 1. You have the wrong crimper for ring terminals. Most Molex crimpers are for the bare Molex pins and sockets that have the two wing portions that roll toward each other when crimped. However most good ratchet crimpers have a little release lever or tab to get you out of trouble; you may have to apply some crimping pressure to relieve the tension on the ratchet to allow the lever to disengage.2. If all else fails, you could cut the wire off flush with the connector barrel (still in the crimp tool) and use a small pin punch to drive it out but be careful not to damage your expensive crimper.3. I personally like the crimpers that put a single indent into the barrel of terminals like the Klein D213-9-NE-CR lineman’s pliers. Align the lug so that the seam is opposite the indent and squeeze until it can pass the “tug test” (I always use the tug test)4. For the power supply you don’t need 14ga wire for the mains supply, but you already have it so you might as well use it.

author: rabbithutch
author_rank: Newbie
timestamp: January 18, 2019, 08:08:39 pm
content: Thank you, Gregg!Clear, comprehensive answer. Great information to have.Yes, I realized that I had used the wrong tool but only after it was too late.Thanks, again!!rh

author: jdraughn
author_rank: Regular Contributor
timestamp: January 19, 2019, 05:12:35 pm
content: Quote from: Gregg on January 16, 2019, 11:23:37 pmMan I hate it when I perform the "tug test", and the test fails, and I end up with an unusable or wonky connector afterward. It's got me to where instead of just crimping once, I crimp a 2 or 3x, rotating the connector a little before each rotation to make sure it's really crimped good - but then I end up with a beat up looking connector.

author: Nusa
author_rank: Super Contributor
timestamp: January 19, 2019, 06:10:00 pm
content: Quote from: rabbithutch on January 16, 2019, 10:50:04 pmIf it's anything like this one, you'll find the spring-loaded ratchet has a protruding nub that can be pressed to release the tension.

author: jfiresto
author_rank: Frequent Contributor
timestamp: January 19, 2019, 08:15:57 pm
content: Quote from: jdraughn on January 19, 2019, 05:12:35 pmI examine the first crimp(s) under a stereo microscope to confirm the wire, die and contact are compatible.This pagesuggests some things to look and watch out for.

author: jfiresto
author_rank: Frequent Contributor
timestamp: January 19, 2019, 08:35:34 pm
content: Quote from: rabbithutch on January 16, 2019, 10:50:04 pmI am sure it has an emergency release somewhere. If you are still stuck, can you post a picture?You snag and turn the ratchet teeth of my one Molex crimper to release the jaws. On another, favored by Tycho/AMP, there is a square nub that you twist as shown by an orbiting arrow.

author: rabbithutch
author_rank: Newbie
timestamp: January 21, 2019, 12:29:05 am
content: Thanks to everyone who responded. Yes, I found the release. I had tried it originally, deducing from its position and spring that it was a release. What I didn't know until reading Gregg's reply was that I needed to apply a little gripping pressure to relieve the tension.Again, thanks to everyone for your answers and your support.rh