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I assembled a few JST PHR-4 connectors with wires (manually crimped SPH-002T-P0.5S crimp terminals with AWG24 wires and inserted it into the PHR-4 connector housing). When I tried to join connector header with the mating PH male pin header on PCB, I find I canno to insert it there. I don't want to apply too much force to connector, to avoid PCB damage. What can be the problem there? I suspect this may be due to I created connector using manual crimp tools, and this can no provide the required accuracy. Here is datasheet.

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  • \$\begingroup\$ You probably crushed the pin openings while you were crimping. Just a guess. \$\endgroup\$ – Daniel Jul 3 '14 at 21:17
  • \$\begingroup\$ You may have also distorted the contact so that when it entered the contact housing the pin entry slot in the housing is not lining up with the pin entry slot in the contact. \$\endgroup\$ – Michael Karas Jul 4 '14 at 2:46
  • \$\begingroup\$ I am not immediately familiar with your contacts but many times when you try to hand crimp with a general purpose low cost crimper you destroy the contact alignment features designed to guide and hold the contact in the housing. As such the pins may have even been inserted rotated 180 degrees from the proper position. This can almost certainly cause failure of contacts to mate properly. \$\endgroup\$ – Michael Karas Jul 4 '14 at 2:51
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Did you use the correct pin crimp tool, either YRS-240 or YRM-240?

http://media.digikey.com/pdf/Data%20Sheets/JST%20PDFs/Hand%20and%20Crimping%20Tools.pdf

These tools run around $1000 each, and are kinda tricky to use. If used correctly though, these make perfect crimps.

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  • \$\begingroup\$ I used PA-09 crimper engineer.jp/_products/pa09/p/pa09_new.jpg I hadn't noticed visually that pin opening were damaged. However, 2.0mm pitch terminals are so small in size. Which area of terminal holds the pin, 1 or 2? s1.postimg.org/8h6nbmhbz/SPH_002_T_P0_5_S.jpg \$\endgroup\$ – sonex Jul 3 '14 at 22:00
  • \$\begingroup\$ I'm not sure. If you take a closeup picture of your crimps that might be more helpful though. \$\endgroup\$ – Daniel Jul 5 '14 at 18:38
  • \$\begingroup\$ Is it possible to use other 2.0mm pitch generic OEM connectors with JST PH male header in place of PHR-4? \$\endgroup\$ – sonex Jul 5 '14 at 20:37

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