Hand Crimp Tool for SL™ Crimp Terminals
HAND CRIMP TOOL
Specification Sheet
Order No. 63811-8800
TYPE 4D
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
Right and Left handed applications
This tool is IPC/WHMA A-620 Class 2 compliant
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: SL™ Crimp Terminal, 24-30 AWG
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
50083-8100 50083-8160 50083-8000 50083-8060
50083
24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125
50083-8114 50083-8170 50083-8114 50083-8070
50087-8100 50087-8130 50087-8000 50087-8060
50087
50087-8114 50087-8160 50087-8014 50087-8099 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125
50087-8030
16-02-0108 40-08-0872 16-02-0077 16-02-0105
70021
16-02-0109
16-02-0078 40-08-0871 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125
16-02-0110
16-02-0091
16-02-0096 70058-0096 16-02-0069 16-02-0150
16-02-0097 70058-0097 16-02-0082 70058-0069
70058
16-02-0098 70058-4096 16-02-0083 70058-0082 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125
16-02-0140
16-02-0137 70058-0083
16-02-0151
16-02-0139 70058-4069
16-02-1109 16-02-0117 16-02-1112 16-02-0119
71851
24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125
16-02-1116 16-02-1117 16-02-1113 71851-0119
Customer to cut off terminal from reel:0.13mm (.005”) maximum front cut-off tab and 0.08mm(.003”) maximum rear cut-off tab.
Doc No. ATS-638118800
Revision: C
Release Date: 05-29-07
Revision Date: 11-14-08
UNCONTROLLED COPY
Page 1 of 8
Hand Crimp Tool for SL™ Crimp Terminals
DEFINITION OF TERMS
BRUSH
BEND UP
BELL MOUTH
ROLLING
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.
Terminal
Series No
50083
50087
70021
70058
71851
Wire Size
AWG
24
26
28
30
24
26
28
30
24
26
28
30
24
26
28
30
24
26
28
30
Doc No. ATS-638118800
Revision: C
mm2
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
mm
In.
mm
In.
mm
In.
mm
In.
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0.77-0.87 .030-.034 1.08 .043 1.50 .059 1.30 .051
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
0-67-0.77 .026-.030 1.06 .042 1.39 .055 1.28 .050
Release Date: 05-29-07
Revision Date: 11-14-08
Pull Force
Profile
Minimum
N
Lb. 24-26 28-30
29.4 6.61
X
19.6 4.41
X
9.8 2.20
X
4.9 1.10
X
29.4 6.61
X
19.6 4.41
X
9.8 2.20
X
4.9 1.10
X
28.9 6.50
X
17.8 4.00
X
11.1 2.50
X
6.7 1.50
X
28.9 6.50
X
17.8 4.00
X
11.1 2.50
X
6.7 1.50
X
28.9 6.50
X
17.8 4.00
X
11.1 2.50
X
6.7 1.50
X
UNCONTROLLED COPY
Page 2 of 8
Hand Crimp Tool for SL™ Crimp Terminals
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as 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.
See Figure 1.
LOCATOR IN
DOWN POSTION
HANDLE WILL
SPRING OPEN
Crimping Terminals
1. Select the desired terminal listed in the
SQUEEZE
preceding charts.
HANDLES
TOGETHER
2. Make sure the center of the locator is in
the down position. With the locator
Figure 1
attached, push the locator button on the
back of the hand tool to bring the
locator forward through the tooling. See Figure 2.
3. While holding the locator button in, load the terminal into the proper
nest opening in the locator based on the wire gauge or terminal type
markings on the hand tooling. See Figure 3.
4. Release the locator button, allowing the locator to return to the
crimping position.
5. Close the tool handle until the first ratchet position engages. See
Figure 4.
6. Insert the properly stripped wire through the terminal and against the
wire stop. See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. Release the handles to open
the jaws.
LOCATOR
PUSHED THRU
TOOLING
Figure 2
PUSH ON THE
LOCATOR BUTTON
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 4
RELEASE
LOCATOR
BUTTON
TERMINAL
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Doc No. ATS-638118800
Revision: C
Release Date: 05-29-07
Revision Date: 11-14-08
Figure 3
UNCONTROLLED COPY
Page 3 of 8
Hand Crimp Tool for SL™ Crimp Terminals
WIRE STOP IS PART OF
THE LOCATOR
WIRE
AGAINST THE
WIRE STOP
TERMINAL
PRE-STRIPPED
WIRE
Figure 5
WIRE
TERMINAL
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
WIRE
8. Remove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
10. On some large O.D. wires, it may not be possible
to insert the wire with the tool partially closed.
Those wires should be inserted with the hand tool
in the open position. Insert the wire above the
terminal in the punch and against the wire stop
then close the tool. See Figure 6.
WIRE STOP
Figure 6
TERMINAL
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 available, actual crimp
height measurements may very slightly. An occasional,
destructive, pull force test should be performed to check
hand tool crimp. Pull Force value Must exceed the Minimum
pull force specifications listed.
LOCATOR
SQUEEZE
HERE
TOP SLOTS OF
HANDTOOL
Locator Replacement
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP HOOKS
See the parts list on the last page of this document for the
proper locator order number. Follow the steps belowSQUEEZE
to
replace the locator.
HERE
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in Figure 7A
with your thumb and index finger. The lower tabs of the
locator should disengage from the hand tool.
3. Lift and pull away from the hand tool. The top locator
hooks should slip out of the top slots easily. See Figure 7A.
Doc No. ATS-638118800
Revision: C
Release Date: 05-29-07
Revision Date: 11-14-08
Figure 7B
Figure 7A
LOWER TABS
UNCONTROLLED COPY
Page 4 of 8
Hand Crimp Tool for SL™ Crimp Terminals
4. To reinstall the new locator, make sure the hand
tool is in the open position.
5. Press the red insert down as far as it will go as
shown in Figure 7B.
6. Holding onto the lower part of the locator with your
thumb and index finger, insert the locators top
hooks (2) into the hand tool top slots.
7. Rotate the locator down and press the lower tabs
into the two bottom slots of the hand tool. To
secure the locator into place, the lower tabs must
snap into place on the hand tool frame.
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
Figure 11
Right or Left Hand Operation
PUSH ON
HANDLE
This hand tool has an added feature that can be
converted from a right handed application to a left handed application. It is necessary to reverse the tooling if
using the left handed application along with the locator. Follow the steps below:
1. The locator must be removed before reversing the
MATCH
tooling.
UP MARKS
2. Remove the M3 BHCS which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side and
replace the M3 BHCS. Make sure the small
markings on the front and back of the hand tool
Figure 12
frame match up and are on the outside of the hand
tool frame. See Figure 11 and 12.
FRONT
4. Do the same thing with the lower tooling and
tighten the M3 screws. Be sure the small markings line up.
5. Reinstall the locator by following the Instructions in the locator replacement section.
BACK
Maintenance
It is recommended that each operator of the tool be made aware of, and
responsible for, the following maintenance steps:
1. Remove dust, moisture, and other contaminants with 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 surfaces are protected with
a thin coat of high quality machine oil. Do not oil excessively. The tool
was engineered for durability but like any other equipment it needs
cleaning and lubrication for a maximum service life of trouble free
crimping. Light oil (such as 30 weight automotive oil) used at the oil
points, every 5,000 crimps or 3 months, will significantly enhance the tool
life.
Doc No. ATS-638118800
Revision: C
Release Date: 05-29-07
Revision Date: 11-14-08
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
UNCONTROLLED COPY
Figure 8
Page 5 of 8
Hand Crimp Tool for SL™ Crimp Terminals
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.
RATCHET RELEASE
LEVER
Miscrimps or Jams
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 up on the ratchet release lever in the movable handle. See Figure 9.
How to Adjust Tool Preload (See Figure 10)
Figure 9
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:
1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link
towards the top of the hand tool frame. This will release the preload adjustment wheel.
2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the
SQUEEZE
HOLD THE HAND
setting wheel clockwise (CW).
THE LINK IN
RATCHET
TOOL
IN POSITION
3. Release the link to lock the setting
THE HANDLE
RELEASE
LEVER
wheel in place.
4. Check the crimp specifications or
conduct a pull test after tool handle
preload force is adjusted.
Warranty
This tool is for electrical terminal crimping
purposes only. This tool is made of the
Figure 10
best quality materials. All vital
SETTING
components are long life tested. All tools
WHEEL
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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
Doc No. ATS-638118800
Revision: C
Release Date: 05-29-07
Revision Date: 11-14-08
UNCONTROLLED COPY
Page 6 of 8
Hand Crimp Tool for SL™ Crimp Terminals
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 the Molex terminals specified for crimping with this tool.
Certification
Molex does not certify or re-certify 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-638118800
Revision: C
Release Date: 05-29-07
Revision Date: 11-14-08
UNCONTROLLED COPY
Page 7 of 8
Hand Crimp Tool for SL™ Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63811-8800
63811-8875
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
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
3
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-638118800
Revision: C
Release Date: 05-29-07
Revision Date: 11-14-08
UNCONTROLLED COPY
Page 8 of 8
