The document provides instructions for crimping a D-sub pin to a wire. First, place the pin in the lower jaw of the crimper with the pin pointing away. Strip 3-5mm of insulation from the wire and insert it into the open end of the pin. Crimp the pin by closing the jaws, securing the first crimp around the wire and the second crimp around the insulation. To finish, you can turn the pin and crimp it again to push the second crimp further into the insulation.

1. D-sub Crimping
First take the pin and place it in the lower jaw of the crimper as shown in fig. 2. To do
this you should have the side of the crimpers that has the part of the jaw that curves downward
(numbers are on this side) facing you. With the pin pointing away from you and making sure that the
pin sleeve is flush against the crimpers as in Fig.1. By holding the pin at the opening of the lower jaw
you can push the pin down by gently closing the crimpers. Only push the pin down into the lower jaw
until the second crimp just touches the bottom of the jaw as in Fig. 2. The pin should be held in the
lower jaw even if the crimpers are opened.
The wire should be stripped 3-5 mm. If you do not strip off enough insulation the first
crimp will not have enough wire to hold onto. If you strip off too much insulation you will not be able
to push the wire in far enough for the second crimp to grab the insulation and hold the wire in properly.
Once the wire is stripped you should be able to put it into the open end of the pin which should be
facing you. Watch too see how far the insulation goes into the pin. No more that 2mm should be
inserted into the second crimp or it may interfere with the first crimp. Secure the crimp by closing the
jaws together tightly. To remove the pin open the jaws and push up under the pin sleeve, do not remove
by pulling up on the wire that is in the pin.
You can secure the insulation by turning the pin around in the lower jaw and gently
crimping the pin again. This will push the second crimp deeper into the insulation.
Crimper 3-5mm 1-2mm
jaws Edge of
upper jaw
Pin sleeve
Insulation
First crimp
Second crimp
Edge of
Wire lower jaw
Fig. 1
Fig. 2
© Classic Technology 2001

2. Crimp pin
Finished crimp pin
This picture shows the pin in the
lower jaw and flush against the
crimper.
Crimp pin in lower jaw of crimpers
© Classic Technology 2001

3. Cross section of wire in D-sub pin
Cross section of lower jaw
3D view of lower jaw
© Classic Technology 2001