Selecting the Right Tool
We also have a less expensive, narrower (4 mm) crimper that can also crimp JST connector, JR, Futaba J, and 0.1" housing crimp pins, though this alternate tool can only crimp the full extent of wire barrel on the JST pins. You can use the following table to help you decide which cavity of which crimping tool you need:
|Tool||Cavity||Crimp Pins||Wire Gauge (AWG)|
|Crimping Tool: 0.1-1.0 mm² Capacity, 16-28 AWG||Outer||0.1" Housing Female |
0.1" Housing Male
|Inner||Tamiya Female |
Mini Tamiya Female
Mini Tamiya Male
|Crimping Tool: 0.08-0.5 mm² Capacity, 20-28 AWG||Outer||0.1" Housing Female |
0.1" Housing Male
Using the Crimping Tool
Prepare the wire by stripping about 1/8" (3 mm) of insulation from the end. Place the wire in the crimp pin, lining it up so that the stripped portion lies between the inner set of tabs on the crimp pin, while insulated wire lies between the outer set of tabs.
Place the wire and crimp pin on the appropriate tooth of the tool’s die, making sure that the insulated end is on the raised and wider half of the tooth. The tabs should point toward the cavity on the other side of the die so that the tool bends them inward around the wire when it closes.
Close the jaws of the tool slowly and completely until they release. The tabs on a properly crimped pin should form one barrel around the wire conductors and another barrel for strain relief around the wire insulation.
Tip: The strain relief barrel sometimes ends up a little overly flattened, making it too wide to fit comfortably into the crimp pin housing. In such situations, you can use a pair of pliers to gently squeeze the wider axis of the barrel into a more cylindrical shape that will slide easily into the housing.
One of Pololu's customers has made a very nice video tutorial that talks about how to make custom cables with Pololu's pre-crimped wires and with self-crimped wires. The section on using Pololu's crimping tool starts at approximately 4:15 and shows the process in detail. One of Pololu's distributors has also made a short video tutorial that shows how to use this crimping tool.
This useful inspection chart (pdf) by JST shows properties of good and bad crimp connections to look out for when checking your own connections.
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Documentation and Resources:
- The Maker Revolution
The Maker Revolution celebrates the creation of new devices and the modification of existing ones - the transition from a consumer buying goods to eventually having a major part in their creation. The Maker Revolution places strong emphasis on free (...
- What is a JST Connector?
JST is a standard of electrical connection used widely across a spectrum of electrical applications. It's defined as a Japanese Solderless Terminal and is manufactured by a company of the same name. The JST range includes a variety of families of con...
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