How do you crimp hard-shell insulated connectors?

[ggggizli]

I ran into exactly the same problem with my Thermador microwave as this guy (https://www.eevblog.com/forum/repair/ge-microwave-oven-with-burnt-connectors-on-thermal-cutoffs-(usa)/) Like many pointed out in that thread, the problem seems to be bad quality connectors on the TCO.

I have a dumb question before I jump in and start ordering parts. How do you crimp hard-shell plastic insulated connectors like shown in attached picture? Is the insulation supposed to be removable? Are there specialty tools that let you do that?

[inse]

You only crimp the exposed metal tab, possibly it’s slipped into the isolation afterwards.
You need a crimping tool for unisolated connectors, don’t try it with the red/blue/yellow pliers.

[MarkF]

Ya, you only crimp the metal part.  Then it clips into the plastic shell.

I just ordered these from Amazon Preciva Dupont Ratcheting Crimper Plier Set.  Notice the rounded crimp at #3 in this picture.  It forms the proper round crimp on the wire insulation.  Areas #1 and #2 form a wedge shape which doesn't work on the insulation.  I have another crimp tool where the insulation crimp is the wedge, 'W' shape, and for Dupont end they don't slip into the shell most of the time.



You need to check the size of your connector if it can be crimped with a Dupont crimp tool.  But, you will need to look for the rounded area for the insulation and the 'W' area for the wire.

[tooki]

Ya, you only crimp the metal part.  Then it clips into the plastic shell.

I just ordered these from Amazon Preciva Dupont Ratcheting Crimper Plier Set.  Notice the rounded crimp at #3 in this picture.  It forms the proper round crimp on the wire insulation.  Areas #1 and #2 form a wedge shape which doesn't work on the insulation.  I have another crimp tool where the insulation crimp is the wedge, 'W' shape, and for Dupont end they don't slip into the shell most of the time.



You need to check the size of your connector if it can be crimped with a Dupont crimp tool.  But, you will need to look for the rounded area for the insulation and the 'W' area for the wire.

That is incorrect advice.

Most open-barrel crimp terminals are designed to have the m-shaped (“type F”) insulation crimp. DuPont connectors are one of the exceptions that require the circular insulation crimp — you see this because of the pointed, angle-cut insulation wings.

The terminal shown in the original post has insulation wings that are cut square, which are typically used with the m-shape crimp (but which can often use the circular crimp).

Edit:
Anyway, OP amazingly didn’t bother to link to the terminal in question in this thread about crimping it, but at least did so in the other thread. It is a 0.25” Faston for 18-14AWG wire, so it is FAR too large a terminal for that crimp tool linked above. A DuPont contact is under half the size of this Faston.

There are any number of affordable crimp tools for open-barrel terminals that should work for this.

Here’s the terminal drawing:
https://www.te.com/commerce/DocumentDelivery/DDEController?Action=showdoc&DocId=Customer+Drawing%7F521011%7FK3%7Fpdf%7FEnglish%7FENG_CD_521011_K3.pdf%7F521011-1