Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
Hand Crimp Tool Specification Sheet
Order No. 63811-3200
Replaces 11-01-0084 (HTR1031E)
And 11-01-0211 (HTR1031E1)
TYPE 2C
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
This tool is RoHS compliant
SCOPE
Products: 14-24 AWG .093” Pin and Socket, Commoning Connector Terminal, Claspcon™, .125” Pin and Socket
Crimp Terminals.
Terminal
Series No.
1189
1190
1380
1381
1457-1
1457-2
1881-2
1973
1973-2
2046
2047
2273
2282
4272
4549
4550
6271
02-09-1103
02-09-1104
02-09-3102
02-09-3104
02-09-5106
02-09-2103
02-09-4104
02-09-6106
02-09-2118
02-09-2119
02-09-6123
02-09-1118
02-09-1119
02-09-5133
02-09-5142
05-02-0048
05-02-0057
Terminal Order No.
Loose Piece
02-09-5111 39-00-0289
39-00-0072 39-00-0291
39-00-0135 39-00-0294
39-00-0288 39-00-0295
02-09-6110
39-00-0106
39-00-0297
02-09-6126
39-00-0302
ÆReel
Wire Size
AWG
mm²
Strip Length
mm
In.
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
39-00-0299
39-00-0301
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
39-00-0304
39-00-0306
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
39-00-0307 39-00-0313
39-00-0308 39-00-0314
39-00-0310 40-01-1191
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
05-02-0047
05-02-0056 18-22
05-02-0058
05-02-0050
05-02-0049
14-16
02-08-1102
16-24
02-09-8104
18-22
02-09-8109
14-18
18-12-2222
16-18
18-12-1222
16-18
02-09-1123 02-09-1140
18-22
18-09-2804 18-09-2807
14-18
02-09-1149
18-22
02-09-2167
14-20
02-09-1206 02-09-5170
14-20
02-09-1212 02-09-5208
18-22
Doc No: ATS-638113200
Revision: F
Insulation Diameter
mm
In.
Release Date: 11-07-03
Revision Date: 09-28-07
0.82-0.32 1.55-2.59 .061-.102 3.30-3.80 .130-.150
2.08-0.82
1.31-0.32
0.82-0.32
2.08-1.31
2.08-1.31
2.08-1.31
0.82-0.32
2.08-0.82
0.82-0.32
2.08-0.52
2.08-0.52
0.82-0.32
3.56 Max.
3.51 Max.
3.51 Max.
4.06 Max.
3.05 Max.
3.05 Max.
1.52-3.05
3.56 Max.
1.52-3.05
3.56 Max.
3.56 Max
1.52-3.05
.140 Max.
.138 Max.
.138 Max.
.160 Max.
.120 Max.
.120 Max.
.060-.120
.140 Max.
.060-.120
.140 Max.
.140 Max
.060-.120
UNCONTROLLED COPY
3.30-3.80
3.30-3.80
3.30-3.80
3.30-3.80
3.30-3.80
3.30-3.80
3.30-3.80
3.60-4.10
3.30-3.80
3.30-3.80
3.30-3.80
3.30-3.80
.130-.150
.130-.150
.130-.150
.130-.150
.130-.150
.130-.150
.130-.150
.140-.160
.130-.150
.130-.150
.130-.150
.130-.150
Page 1 of 8
Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Terminal
Series No.
Reel
AWG
mm²
mm
In.
mm
In.
Loose Piece
6310
02-09-1211 02-09-5206
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
7238
02-09-1112
14-18 2.08-0.82 3.56 Max. .140 Max. 3.60-4.10 .140-.160
Customer to cut off terminal from reel: 0.18mm (.007”) maximum Cut-off Tab.
Æ
Æ
DEFINITION OF TERMS
BEND UP
ROLLING
BRUSH
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
CRIMP
TWISTING
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 5).
Terminal Series No.
1189
Hand Tool
Locator
1
1190
1
1380
1
1381
1
1457-1
2
1457-2
2
Doc No: ATS-638113200
Revision: F
Wire Size
AWG
14
16
18
20
14
16
18
20
18
20
22
18
20
22
18
20
22
14
16
mm2
2.08
1.31
0.82
0.52
2.08
1.31
0.82
0.52
0.82
0.52
0.32
0.82
0.52
0.32
0.82
0.52
0.32
2.08
1.31
Conductor Crimp
Height (REF)
mm
In.
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
Release Date: 11-07-03
Revision Date: 09-28-07
Conductor
Crimp Width (Ref)
mm
In.
2.30
.090
2.30
.090
1.70
.067
1.70
.067
2.30
.090
2.30
.090
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
2.30
.090
2.30
.090
UNCONTROLLED COPY
Pull Force Min.
Profile
N
178.0
155.0
111.3
66.8
178.0
155.8
111.3
66.8
111.3
66.8
53.4
111.3
66.8
53.4
111.3
66.8
53.4
178.0
155.8
A
X
X
Lb.
40.00
35.00
25.00
15.00
40.00
35.00
25.00
15.00
25.00
15.00
12.00
25.00
15.00
12.00
25.00
15.00
12.00
40.00
35.00
B
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 2 of 8
Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
Terminal Series No.
Hand Tool
Locator
1881-2
1
1973
2
1973-2
1
Æ2046
Æ2047
N/A
N/A
2273
1
2282
1
4272
4549
1
1
4550
1
6271
1
6310
1
7238
1
Doc No: ATS-638113200
Revision: F
Wire Size
AWG
16
18
20
22
24
18
20
22
14
16
18
16
18
16
18
18
20
22
14
16
18
18
20
22
14
16
18
20
14
16
18
22
18
20
22
14
16
18
20
14
16
18
mm2
1.31
0.82
0.52
0.32
0.20
0.82
0.52
0.32
2.08
1.31
0.82
1.31
0.82
1.31
0.82
0.82
0.52
0.32
2.08
1.31
0.82
0.82
0.52
0.32
2.08
1.31
0.82
0.52
2.08
1.31
0.82
0.52
0.82
0.52
0.32
2.08
1.31
0.82
0.52
2.08
1.31
0.82
Conductor Crimp
Height (REF)
mm
In.
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.23-1.33 .049-.052
1.38-1.48 .054-.058
1.38-1.48 .054-.058
1.38-1.48 .054-.058
Release Date: 11-07-03
Revision Date: 09-28-07
Conductor
Crimp Width (Ref)
mm
In.
2.30
.090
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
2.30
.090
2.30
.090
1.70
.067
2.30
.090
2.30
.090
2.30
.090
2.30
.090
1.70
.067
1.70
.067
1.70
.067
2.30
.090
2.30
.090
1.70
.067
1.70
.067
1.70
.067
1.70
.067
2.30
.090
2.30
.090
1.70
.067
1.70
.067
2.30
.090
2.30
.090
1.70
.067
1.70
.067
1.70
.067
1.70
.067
1.70
.067
2.30
.090
1.70
.067
1.70
.067
1.70
.067
2.30
.090
2.30
.090
2.30
.090
UNCONTROLLED COPY
Pull Force Min.
Profile
N
155.8
111.3
66.8
53.4
35.6
155.8
80.1
53.4
178.0
155.8
111.3
200.3
155.8
200.3
155.8
89.0
62.3
44.5
178.0
155.8
111.3
89.0
62.3
44.5
178.0
155.8
111.3
66.8
178.0
155.8
111.3
66.8
89.0
62.3
44.5
178.0
155.8
89.0
62.3
178.0
155.8
111.3
A
X
Lb.
35.00
25.00
15.00
12.00
8.00
35.00
18.00
12.00
40.00
35.00
25.00
45.00
35.00
45.00
35.00
20.00
14.00
10.00
40.00
35.00
25.00
20.00
14.00
10.00
40.00
35.00
25.00
15.00
40.00
35.00
25.00
15.00
20.00
14.00
10.00
40.00
35.00
20.00
14.00
40.00
35.00
25.00
B
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 3 of 8
Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects damage can
occur to the tool or die.
Open the tool by squeezing the handles together, at the end of the
closing stroke, the ratchet mechanism will release the handles, and
the hand tool will spring open.
JAWS OPEN
LOCATOR
Crimping Terminals
1. Select the desired terminal listed in the preceding charts. Make
sure that the proper locator is mounted on the tool.
2. Swing the terminal locator away from the crimp tool shown in
Figure 2. Some terminals with large insulation grips may
interfere with the crimp tooling when swinging the locator into
position. The terminal must then be loaded into the locator in
the closed/crimp position.
Figure 1
TERMINAL
SWING OPEN
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
Figure 2
TERMINAL
IN PLACE
3. When using 63811-3275 (Locator No. 1), press down on the wire stop on the locator as shown in Figure 2.
Insert the proper terminal into the proper nest opening. Make sure when choosing the nest opening, it will
correspond with the A or B profile on the hand tool.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Gently touch the wire stop with the end of the wire. See Figure 3.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Doc No: ATS-638113200
Revision: F
Release Date: 11-07-03
Revision Date: 09-28-07
UNCONTROLLED COPY
Page 4 of 8
Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
7. Remove the crimp terminal from the terminal locator by
pressing down on the wire stop and gently pulling on the wire.
The terminal locator can by in either position
8. Visually inspect the crimped terminal for proper crimp location
and crimp height.
WIRE STOP
WIRE
✴ Crimping Terminals without a Locator
1. With the hand tool in the open position, select the proper
profile.
LOCATOR
TERMINAL
2. Position the terminal in the proper profile; partially close the
IN PLACE
hand tool until the terminal is held in place. The terminal
should be positioned so that the front of the insulation grips is
flush with the front face of the insulation tooling. See Figure
3A.
WIRE STOP
3. Gently slip the wire into the terminal, and then position the
insulation and stripped strands into the terminal insulation and
WIRE
conductor grips. Note: No wire stop is provided. If the wire
AGAINST STOP
will not fit into the partially closed tool, due to large insulation
Figure 3
diameter, the terminal and wire must then be placed in the
open tool. Applying slight downward pressure on the wire may help hold the terminal in place while crimping.
4. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
TERMINAL FLUSH WITH
INSULATION TOOLING
Note:
A crimp height chart is provided with this manual as Reference Only.
Due to the wide range of wires, strands, insulation diameters, and
durometers, actual crimp height measurements may very slightly. An
occasional, destructive, pull force test should be preformed to check
hand tool crimp. Pull Force value Must exceed the Minimum pull
force specifications listed on pages 2 and 3.
INSULATION TOOLING
Locator Change Over
Figure 3A
Two styles of locators are provided with the crimp hand tool 63811-3200. They are locator no. 1 (63811-3275),
which is black and locator no.2 (63811-3276), which is gray. Make sure the desired style of locator is installed for
the proper terminal and wire. Follow the steps below to change the locators.
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the
top of the brass pivot shaft. See Figure 4.
4. Replace it with the desired locator by putting over the brass pivot shaft and snapping it into place.
Doc No: ATS-638113200
Revision: F
Release Date: 11-07-03
Revision Date: 09-28-07
UNCONTROLLED COPY
Page 5 of 8
Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
LIFT UP
LOCATOR
Maintenance
It is recommended that each operator of the tool be made
aware of, and responsible for, the following maintenance
steps:
JAWS
OPEN
PRESS DOWN
1. Remove dust, moisture, and other contaminants with
ON BRASS
PIVOT SHAFT
a clean brush, or soft, lint free cloth.
2. Do not use any abrasive materials that could damage
the tool.
3. Make certain all pins; pivot points and bearing
SWING
surfaces are protected with a thin coat of high quality
machine oil. Do not oil excessively. The 63811-3200 LOCATOR
OPEN
was engineered for durability but like any fine piece of
Figure 4
equipment it needs cleaning and lubrication for a
maximum service life of trouble free crimping. Light
oil such as 30 weights automotive oil used at the oil points shown in Figure 6, every 5,000 crimps or 3 months,
will significantly enhance the tool life.
4. Wipe excess oil from hand tool, particularly from crimping area. Oil transferred from the crimping area onto
certain terminations may affect the electrical characteristics of an application.
5. When tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping dies,
and store the tool in a clean, dry area.
Miscrimps or Jams
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Should this tool ever become stuck or jammed in a partially
closed position, Do Not force the handles open or closed.
The tool will open easily by pressing the ratchet release
lever (See Figure 6).
How to Adjust Tool Preload (See Figure 6)
This hand tool is factory preset to 25-45 LBS. preload. It
may be necessary over the life of the tool to adjust tool
handle preload force. Listed below are the steps required
to adjust the crimping force of the hand tool to obtain
proper crimp conditions:
Figure 5
1. Remove or fold back the handle grip from the handle to expose the eccentric axle.
2. Remove the locking screw with a 2mm hex wrench. The wrench set (63810-0101), is not supplied. It is sold
separately from the hand tool.
3. Turning the eccentric axle counter-clockwise (CCW) will increase handle force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. Check the crimp specifications after tool handle preload force is adjusted.
Doc No: ATS-638113200
Revision: F
Release Date: 11-07-03
Revision Date: 09-28-07
UNCONTROLLED COPY
Page 6 of 8
Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
Warranty
This tool is for electrical terminal crimping purposes
only. This tool is made of the best quality materials.
All vital components are long life tested. All tools
are warranted to be free of manufacturing defects
for a period of 30 days. Should such a defect
occur, we will repair or exchange the tool free of
charge. This repair or exchange will not be
applicable to altered, misused, or damaged tools.
This tool is designed for hand use only. Any
clamping, fixturing, or use of handle extensions
voids this warranty.
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
ECCENTRIC AXLE
HANDLE
GRIP
REMOVED
WRENCH SET
LOCKING
(SOLD
SEPERATELY) SCREW
RATCHET
RELEASE LEVER
Figure 6
HANDLE
GRIP
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and
tooling.
CAUTIONS
1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended for
production use. Repetitive use of this tool should be avoided.
2. Insulated rubber handles are not protection against electrical shock.
3. Wear eye protection at all times.
4. Use only Molex Terminal specified for crimping with the tool.
Certification
Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools.
%
%
%
This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull
testing.
If the tool does not meet minimum pull force values, handle preload should be increased and the pull test
rerun, (See How To Adjust Preload).
When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.
Doc No: ATS-638113200
Revision: F
Release Date: 11-07-03
Revision Date: 09-28-07
UNCONTROLLED COPY
Page 7 of 8
Hand Crimp Tool for Standard .093”Pin and Socket Crimp Terminals
PARTS LIST
Item Number
1
2
3
4
5
Order Number
63810-0101
63810-0102
63810-0103
63811-3275
63811-3276
Description
Wrench Set (Not included)
Locator Base Assembly
Repair Kit (Not included)
Locator #1-Black
Locator #2-Gray
Quantity
0
1
0
1
1
5
1
3
4
M4 X 5LG
BHCS
RATCHET
RELEASE LEVER
2
3
Figure 7
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
Doc No: ATS-638113200
Revision: F
Release Date: 11-07-03
Revision Date: 09-28-07
UNCONTROLLED COPY
Page 8 of 8
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