Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63819-1100
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 WHMA-IPCA620 Class 2 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.36mm (.093") Diameter, Standard .093" Pin and Socket Crimp Terminals, 14-20 AWG,
3.18mm (.125") Diameter, Standard .125" Pin and Socket Crimp Terminals, 16-18 AWG,
and Commoning Terminals, 14-16 AWG.
Terminal
Series No.
1189
1190
1457-2
1973-2
2046
2047
4549
4550
7238
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
AWG
mm²
mm
In.
mm
In.
• Reel
02-09-1103 39-00-0288
02-09-1104 39-00-0289
02-09-5106 39-00-0294
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
02-09-5111 39-00-0295
39-00-0072
02-09-2103 39-00-0297
02-09-6106 39-00-0299
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
02-09-6110
05-02-0050
05-02-0049 14-16 2.08-1.31 3.56 Max. .140 Max. 3.30-3.80 .130-.150
02-09-8109
14-18 2.08-0.82 4.06 Max. .160 Max. 3.30-3.80 .130-.150
18-12-2222
16-18 1.31-0.82 3.05 Max. .120 Max. 3.30-3.80 .130-.150
18-12-1222
16-18 1.31-0.82 3.05 Max. .120 Max. 3.30-3.80 .130-.150
02-09-2167
14-20 2.08-0.52 3.56 Max. .140 Max. 3.30-3.80 .130-.150
02-09-1206 02-09-5170
14-20 2.08-0.52 3.56 Max. .140 Max. 3.30-3.80 .130-.150
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.
See Conditions on page 3.
Doc No: ATS-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Page 1 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
DEFINITION OF TERMS
BEND UP
CONDUCTOR
CRIMP
INSULATION CRIMP
▲SEE NOTE
BRUSH
BELL MOUTH
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.
OVERLAP FORM GEOMETRY
▲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
CONDITIONS:
OVERLAP
INSULATION
CRIMP
ANVIL
WIRE
After crimping, the conductor profiles should measure the following.
Terminal Series No
1189
1190
1457-2
1973-2
2046
Doc No: ATS-638191100
Revision: B
Wire Size
AWG mm2
14 2.08
16 1.31
18 0.82
20 0.52
14 2.08
16 1.31
18 0.82
20 0.52
14 2.08
16 1.31
14 2.08
16 1.31
18 0.82
16 1.31
18 0.82
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
1.62 - 1.72 .064-.068 2.36 .093 3.25 .128 3.50 .138
1.46 – 1.56 .057-.061 2.36 .093 3.09 .122 3.43 .135
1.35 – 1.45 .053-.057 2.08 .082 2.74 .108 3.09 .122
1.30 – 1.40 .051-.055 2.08 .082 2.65 .104 3.02 .119
1.62 - 1.72 .064-.068 2.36 .093 3.25 .128 3.50 .138
1.46 – 1.56 .057-.061 2.36 .093 3.09 .122 3.43 .135
1.35 – 1.45 .053-.057 2.08 .082 2.74 .108 3.09 .122
1.30 – 1.40 .051-.055 2.08 .082 2.65 .104 3.02 .119
1.62 - 1.72 .064-.068 2.40 .094 3.25 .128 3.53 .139
1.52 – 1.62 .060-.064 2.35 .093 3.16 .124 3.48 .137
1.62 – 1.72 .064-.068 2.39 .094 3.23 .127 3.50 .138
1.52 – 1.62 .060-.064 2.35 .093 3.15 .124 3.44 .135
1.37 – 1.47 .054-.058 2.09 .082 2.76 .109 3.07 .121
1.65 – 1.75 .065-.069 2.38 .094 3.30 .130 3.55 .140
1.57 – 1.67 .062-.066 2.34 .092 3.19 .126 3.47 .137
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Page 2 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Terminal Series No
2047
4549
4550
7238
Wire Size
AWG mm2
16 1.31
18 0.82
14 2.08
16 1.31
18 0.82
20 0.52
14 2.08
16 1.31
18 0.82
20 0.52
14 2.08
16 1.31
18 0.82
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
1.65 – 1.75 .065-.069 2.38 .094 3.30 .130 3.55 .140
1.57 – 1.67 .062-.066 2.34 .092 3.19 .126 3.47 .137
1.57 - 1.67 .062-.066 2.39 .094 3.20 .126 3.49 .137
1.46 – 1.56 .057-.061 2.35 .093 3.10 .122 3.46 .136
1.33 – 1.43 .052-.056 2.08 .082 2.72 .107 3.08 .121
1.25 – 1.35 .049-.053 2.07 .081 2.65 .104 3.00 .118
1.57 - 1.67 .062-.066 2.39 .094 3.20 .126 3.49 .137
1.46 – 1.56 .057-.061 2.35 .093 3.10 .122 3.46 .136
1.33 – 1.43 .052-.056 2.08 .082 2.72 .107 3.08 .121
1.25 – 1.35 .049-.053 2.07 .081 2.65 .104 3.00 .118
1.69 – 1.79 .067-.070 2.40 .094 3.24 .128 3.51 .138
1.65 – 1.75 .065-.069 2.38 .094 3.24 .128 3.51 .138
1.59 – 1.69 .063-.067 2.37 .093 3.18 .125 3.46 .136
Wire Size
Pull Force Minimum
Profile
Locator
AWG mm2
N
Lb.
A
B
Order No.
Color
14
2.08
178.0
40.00
X
16
1.31
155.0
35.00
X
1189
63819-1175
Red
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
14
2.08
178.0
40.00
X
16
1.31
155.0
35.00
X
1190
63819-1175
Red
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
14
2.08
178.0
40.00
X
1457-2
63819-1176 Yellow
16
1.31
155.0
35.00
X
14
2.08
178.0
40.00
X
1973-2
16
1.31
155.0
35.00
X
63819-1176 Yellow
18
0.82
111.3
25.00
X
16
1.31
155.0
35.00
X
2046
63819-1177 Gray
18
0.82
111.3
25.00
X
16
1.31
155.0
35.00
X
2047
63819-1177 Gray
18
0.82
111.3
25.00
X
14
2.08
178.0
40.00
X
16
1.31
155.0
35.00
X
4549
63819-1175
Red
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
14
2.08
178.0
40.00
X
16
1.31
155.0
35.00
X
4550
63819-1175
Red
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
14
2.08
178.0
40.00
X
7238
16
1.31
155.0
35.00
X
63819-1175
Red
18
0.82
111.3
25.00
X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges
are recommended:
1. Profile A: 3.00mm - 2.20mm (.118 - 087 inch)
2. Profile B: 2.85mm -2.00mm (.112 - .079 inch)
Terminal Series No
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.
Doc No: ATS-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Page 3 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
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 preformed to check hand tool crimp. Pull Force value Must exceed
the Minimum pull force specifications listed.
HANDLE WILL
SPRING OPEN
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.
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.
Figure 1
Crimping Terminals
1. Select the desired terminal listed from the preceding charts and install the proper locator (See chart above and
see Locator Installation 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.
RELEASE
LOCATOR
BUTTON
LOCATOR IN
DOWN POSTION
TERMINAL
LOCATOR
PUSHED THRU
TOOLING
LOCATOR
BUTTON
PUSHED IN
Figure 2
PUSH ON THE
LOCATOR BUTTON
TERMINAL
Figure 3
3. While holding in the locator button, 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.
Doc No: ATS-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
UNCONTROLLED COPY
Figure 4
Page 4 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
WIRE STOP IS
PART OF THE
LOCATOR
WIRE AGAINST
THE WIRE
STOP
TERMINAL
PRE-STRIPPED
WIRE
Figure 5
TERMINAL
WIRE
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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
WIRE STOP
Figure 6
Locator Installation
TERMINAL
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.
LOCATOR
SQUEEZE
HERE
JAWS OPEN
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
SQUEEZE
HERE
PULL OPEN
TOOLING
TOOLING
M3 BHCS
TOP HOOKS
Figure 8
Figure 7B
PUSH ON
HANDLE
Figure 7A
LOWER TABS
Doc No: ATS-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Page 5 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
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 locator top hooks
MATCH
(2) into the hand tool top slots.
UP MARKS
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.
Figure 9
Right or Left Hand Operation
BACK
FRONT
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 along with the locator if using the left handed application. Follow
the steps below:
1. The locator must be removed before reversing the tooling.
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 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 the M3 screws. Be sure
the small markings line up.
5. Reinstall the locator by following the Instructions in the locator replacement
section.
Maintenance
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
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.
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.
Doc No: ATS-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Figure 10
RATCHET RELEASE
LEVER
Figure 11
Page 6 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
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
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
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
How to Adjust Tool Preload
(See Figure 10)
This hand tool is factory preset to 25-45
LBS. preload. It may be necessary over
SETTING
the life of the tool to adjust tool handle
WHEEL
preload force. Listed below are the steps
required to adjust the crimping force of the hand tool to obtain proper crimp conditions:
Figure 12
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.
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.
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.
Doc No: ATS-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Page 7 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
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-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Page 8 of 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
PARTS LIST
Item Number
REF
1
1
1
2
3
Order Number
63819-1100
63819-1175
63819-1176
63819-1177
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly (Red)
Locator Assembly (Yellow)
Locator Assembly (Gray)
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638191100
Revision: B
Release Date: 01-09-08
Revision Date: 08-07-12
UNCONTROLLED COPY
Page 9 of 9
