Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure Crimp Terminals
Hand Crimp
Tool
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63819-0800
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
Dies and Locator from this tool can be used in the Battery Powered Tool Order No.63816-0200 (110 V) or
63816-0250 (220 V), with the use of the 63816-0800 Crimp Head
Many different tool kits can be used with a single Battery Powered Crimp Tool
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1.57mm (.062") Diameter, Standard .062" Pin and Socket Crimp Terminals, 24-30 AWG
2.50mm (.098") Pitch SPOX™ Wire-to-Wire Male Crimp Terminals, 22-28 AWG
2.54mm (.100) KK® High Pressure Crimp Terminals, 22-30 AWG
2.50mm (.098") Pitch Wire-to-Wire Male Crimp Terminal, 22-28 AWG.
Terminal
Series No.
1854
1855
5241
7879
35053
Terminal Order No.
Wire Size
Insulation Diameter
Loose Piece
(1) Reel
AWG
mm²
mm
In.
02-06-2132 02-06-6144 02-06-2131 02-06-6143
02-06-6135 04-01-0811 02-06-6130 04-01-0809
24-30 0.20-0.05 1.02-1.78 .040-.070
02-06-6136 39-00-0335 02-06-6137 39-00-0280
02-06-6139 39-00-0337 02-06-6138 39-00-0336
02-06-1132 02-06-5148 02-06-1131 02-06-5147
02-06-1143 04-01-0812 02-06-1141 04-01-0810
24-30 0.20-0.05 1.02-1.78 .040-.070
02-06-5135 39-00-0339 02-06-5130 39-00-0338
02-06-5139 39-00-0341 02-06-5138 39-00-0340
08-70-0103
08-70-0102
22-28 0.35-0.08 1.15-1.90 .045-.075
08-50-0005 50-29-1745 08-50-0004 50-29-1635
08-55-0127 46999-0101 08-55-0124 50-29-1744 22-30 0.35-0.05 1.02-1.57 .040-.062
08-55-0129
08-55-0128 50-29-1900
35053-9002
22-28 0.35-0.08 1.15-1.90 .045-.075
(1) Customer to cut off terminal from reel: 0.13mm (.005”) maximum Cut-off Tab.
Doc No: ATS-638190800
Revision: D
Release Date: 10-25-07
Revision Date: 09-16-15
UNCONTROLLED COPY
Strip Length
mm
In.
3.17-3.96 .125-.156
3.17-3.96 .125-.156
2.60-3.20 .102-.126
2.54-3.17 .100-.125
2.30-2.90 .091-.114
Page 1 of 8
Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure Crimp Terminals
BEND UP
DEFINITION OF TERMS
BRUSH
BELL MOUTH
INSULATION
CRIMP
▲SEE NOTE
CONDUCTOR
CRIMP
ROLLING
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.
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design and/or
insulation diameter range, this tool uses “overlap” form
geometry in the insulation punch. This produces an
overlap insulation crimp (A620 – compliant). While the
insulation punch profile may appear “lopsided”, this is
a normal condition for this tool. See figure to the right.
(Some tools with multiple crimp pockets may not have
the “overlap” profile on all pockets).
PUNCH
OVERLAP FORM GEOMETRY
OVERLAP
INSULATION
CRIMP
CONDITIONS:
After crimping, the conductor profiles should measure
the following. See Notes below.
Terminal
Series No
1854
1855
5241
7879
35053
Doc No: ATS-638190800
Revision: D
Wire Size
AWG mm2
24
0.20
26
0.12
28
0.08
30
0.05
24
0.20
26
0.12
28
0.08
30
0.05
22
0.35
24
0.20
26
0.12
28
0.08
22
0.35
24
0.20
26
0.12
28
0.08
30
0.05
22
0.35
24
0.20
26
0.12
28
0.08
ANVIL
WIRE
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
mm
In.
mm
In.
mm
In.
mm
In.
0.69-0.79 .027-.031 1.41 .055 1.42 .056 1.63 .064
0.65-0.75 .025-.029 1.37 .053 1.38 .054 1.41 .055
0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055
0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055
0.69-0.79 .027-.031 1.41 .055 1.42 .056 1.63 .064
0.65-0.75 .025-.029 1.37 .053 1.38 .054 1.41 .055
0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055
0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055
0.72-0.82 .028-.032 1.43 .056 1.46 .058 1.63 .064
0.72-0.82 .028-.032 1.43 .056 1.44 .057 1.63 .064
0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055
0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055
0.70-0.80 .028-.031 1.41 .055 1.42 .056 1.63 .064
0.70-0.80 .028-.031 1.41 .055 1.42 .056 1.63 .064
0.65-0.75 .025-.029 1.37 .053 1.37 .053 1.41 .055
0.65-0.75 .025-.029 1.37 .053 1.37 .053 1.41 .055
0.65-0.75 .025-.029 1.37 .053 1.37 .053 1.41 .055
0.72-0.82 .028-.032 1.43 .056 1.46 .058 1.63 .064
0.72-0.82 .028-.032 1.43 .056 1.44 .057 1.63 .064
0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055
0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055
Release Date: 10-25-07
Revision Date: 09-16-15
UNCONTROLLED COPY
Page 2 of 8
Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure Crimp Terminals
Terminal
Series No
1854
1855
5241
7879
35053
Wire Size
AWG mm2
24
0.20
26
0.12
28
0.08
30
0.05
24
0.20
26
0.12
28
0.08
30
0.05
22
0.35
24
0.20
26
0.12
28
0.08
22
0.35
24
0.20
26
0.12
28
0.08
30
0.05
22
0.35
24
0.20
26
0.12
28
0.08
Profile
Locator
Pull Force
Minimum
A
B
C
D
Order No. Color
N
Lb. 26-30 22-24 22-24 26-30
28.9 6.50
X
17.8 4.00
X
63819-0875 Red
11.1 2.50
X
6.7 1.50
X
28.9 6.50
X
17.8 4.00
X
63819-0875 Red
11.1 2.50
X
6.7 1.50
X
39.2 8.80
X
29.4 6.60
X
63819-0875 Red
19.6 4.40
X
9.8 2.20
X
44.8 10.00
X
28.9 6.50
X
17.8 4.00
X
63819-0875 Red
11.1 2.50
X
6.7 1.50
X
39.2 8.80
X
29.4 6.60
X
63819-0876 Yellow
19.6 4.40
X
9.8 2.20
X
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Note:
A crimp height chart is provided with this document 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
LOCATOR
HANDLE WILL
IN DOWN
SPRING
OPEN
Minimum pull force specifications listed.
POSTION
OPERATION
CAUTION: Crimp only the Molex
terminals listed in the scope for this
tool. Do not crimp hardened objects
as damage can occur to the tool
frame and/or crimp dies.
SQUEEZE
HANDLES
TOGETHER
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.
Doc No: ATS-638190800
Revision: D
Release Date: 10-25-07
Revision Date: 09-16-15
Figure 2
PUSH ON THE
LOCATOR BUTTON
Figure 1
UNCONTROLLED COPY
Page 3 of 8
Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure Crimp Terminals
Crimping Terminals
1. Select the desired terminal listed in the preceding charts and install the proper locator. See chart above and
locator replacement on page 5.
2. Make sure the center of the locator is in the down position. With the locator 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.
LOCATOR
PUSHED THRU
TOOLING
RELEASE
LOCATOR BUTTON
LOCATOR
LOCATOR
BUTTON
PUSHED IN
TERMINAL
4.
5.
6.
7.
Figure 3
TERMINAL
Release the locator button, allowing the locator to return to the crimping position.
Close the tool handle until the first ratchet position engages. See Figure 4.
Insert the properly stripped wire through the terminal and against the wire stop. See Figure 5.
Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws.
TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE STOP IS PART
OF THE LOCATOR
PRE-STRIPPED
WIRE
Figure 5
WIRE
TERMINAL
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Doc No: ATS-638190800
Revision: D
Release Date: 10-25-07
Revision Date: 09-16-15
UNCONTROLLED COPY
Page 4 of 8
Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure Crimp Terminals
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
TERMINAL
Locator Replacement
Figure 6
LOCATOR
See the parts list on the last page of this document
for the proper locator order number. Follow the
steps below to replace the locator.
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.
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.
Right or Left Hand Operation
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
tooling.
Doc No: ATS-638190800
Revision: D
Release Date: 10-25-07
Revision Date: 09-16-15
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
TOP SLOTS OF
HANDTOOL
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP HOOKS
Figure 7B
LOWER TABS
JAWS OPEN
TOOLING
PULL OPEN
TOOLING
M3 BHCS
Figure 8
PUSH ON
HANDLE
UNCONTROLLED COPY
Page 5 of 8
Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure Crimp Terminals
2. Remove the M3 BHCS which is holding the upper
MATCH
tooling.
UP MARKS
3. Flip the upper tooling to the opposite side and replace
the M3 BHCS. Make sure the small markings on the
Figure 9
front and back of the hand tool frame match up and
are on the outside of the hand tool frame. See Figure
8 and 9.
4. Do the same thing with the lower tooling and tighten
FRONT
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
LUBRICATION POINTS
thin coat of high quality machine oil. Do not oil excessively. The tool was
(BOTH SIDES) LIGHT OIL
engineered for durability but like any other equipment it needs cleaning and
(EVERY 3 MONTHS OR
5,000 CRIMPS)
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.
Figure 10
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
11.
How to Adjust Tool Preload (See Figure 12)
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 11
1. Hold the hand tool in the palm of your hand as shown in Figure 12. 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 setting wheel clockwise (CW).
3. Release the link to lock the setting wheel in place.
4. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.
Doc No: ATS-638190800
Revision: D
Release Date: 10-25-07
Revision Date: 09-16-15
UNCONTROLLED COPY
Page 6 of 8
Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure 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.
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
Figure 12
SETTING
WHEEL
CAUTION: Molex crimp specifications are valid only when used with Molex terminals 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 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. 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-638190800
Revision: D
Release Date: 10-25-07
Revision Date: 09-16-15
UNCONTROLLED COPY
Page 7 of 8
Hand Crimp Tool For .062” Pin and Socket, SPOX™ and KK® High Pressure Crimp Terminals
PARTS LIST
Item Number
REF
1
1
2
3
Order Number
63819-0800
63819-0875
63819-0876
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly (Red)
Locator Assembly (Yellow)
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638190800
Revision: D
Release Date: 10-25-07
Revision Date: 09-16-15
UNCONTROLLED COPY
Page 8 of 8
