Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning Crimp Terminals
HAND CRIMP TOOL
Specification Sheet
Order No. 63819-1200
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 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, 18-22 AWG,
Claspcon Pin and Socket Crimp Terminals, 16-24 AWG, and Commoning Terminals, 18-22 AWG.
Æ
Insulation Diameter
Strip Length
Terminal Order No.
Wire Size
Loose Piece
+ Reel
AWG
mm²
mm
In.
mm
In.
02-09-2118 02-09-6126
1380
18-22 0.82-0.32
1.52-3.05 .060-.120 3.30-3.80 .130-.150
02-09-6123 39-00-0302
02-09-1118 39-00-0307
1381
02-09-1119 39-00-0308
18-22 0.82-0.32
1.52-3.05 .060-.120 3.30-3.80 .130-.150
02-09-5133
02-09-5142
1457-1
05-02-0048
05-02-0047 18-22 0.82-0.32
1.55-2.59 .061-.102 3.30-3.80 .130-.150
1.50-3.50 .059-.138 3.30-3.80 .130-.150
1881-2
02-08-1102
16-24 1.31-0.22
3.51
Max. .138 Max. 3.30-3.80 .130-.150
1973
02-09-8104
18-22 0.82-0.32
2273
02-09-1123
18-22 0.82-0.32
1.52-3.05 .060-.120 3.30-3.80 .130-.150
4272
02-09-1149
18-22 0.82-0.32
1.52-3.05 .060-.120 3.30-3.80 .130-.150
6271
02-09-1212
18-22 0.82-0.32
1.52-3.05 .060-.120 3.30-3.80 .130-.150
+ Customer to cut off terminal from reel: 0.18mm (.007”) maximum Cut-off Tab.
To Achieve IPC-A-620 Class 2 Crimps, the following wire insulation diameter limits are recommended:
1. Terminal #1881-2 maximum diameter - 3.14mm (.124 inch)
2. Terminal #1973 maximum diameter - 2.85mm (.112 inch)
3. 16 - 20 AWG Profile minimum diameter (all terminals) - 1.70mm (.067 inch)
Terminal
Series No.
Æ
Æ
Æ
Doc No: ATS-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 1 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning Crimp Terminals
DEFINITION OF TERMS
BRUSH
BEND UP
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
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.
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal Series No
1380
1381
1457-1
1881-2
1973
2273
4272
6271
Doc No: ATS-638191200
Revision: A
Wire Size
AWG mm2
18 0.82
20 0.52
22 0.32
18 0.82
20 0.52
22 0.32
18 0.82
20 0.52
22 0.32
16 1.31
18 0.82
20 0.52
22 0.32
24 0.22
18 0.82
20 0.52
22 0.32
18 0.82
20 0.52
22 0.32
18 0.82
20 0.52
22 0.32
18 0.82
20 0.52
22 0.32
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
1.48 – 1.58 .058-.062 1.93 .076 2.88 .113 2.59 .102
1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
1.48 – 1.58 .058-.062 1.93 .076 2.88 .113 2.59 .102
1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
1.48 – 1.58 .058-.062 1.93 .076 2.88 .113 2.59 .102
1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
1.52 – 1.62 .060-.064 1.95 .077 2.96 .117 2.63 .104
1.48 – 1.58 .058-.062 1.93 .076 2.88 .113 2.59 .102
1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
1.27 – 1.37 .050-.054 1.90 .075 2.30 .091 2.28 .090
1.48 – 1.58 .058-.062 1.93 .076 2.88 .113 2.59 .102
1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
1.37 – 1.47 .054-.058 1.92 .076 2.75 .108 2.58 .102
1.27 – 1.37 .050-.054 1.90 .075 2.63 .104 2.48 .098
1.25 – 1.35 .049-.053 1.88 .074 2.35 .093 2.30 .091
1.37 – 1.47 .054-.058 1.92 .076 2.75 .108 2.58 .102
1.27 – 1.37 .050-.054 1.90 .075 2.63 .104 2.48 .098
1.25 – 1.35 .049-.053 1.88 .074 2.35 .093 2.30 .091
1.37 – 1.47 .054-.058 1.90 .076 2.75 .108 2.58 .102
1.27 – 1.37 .050-.054 1.90 .075 2.63 .104 2.48 .098
1.25 – 1.35 ..049-.053 1.88 .074 2.35 .093 2.30 .091
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 2 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning Crimp Terminals
Terminal Series No
1380
1381
1457-1
1881-2
1973
2273
4272
6271
Wire Size
AWG
18
20
22
18
20
22
18
20
22
16
18
20
22
24
18
20
22
18
20
22
18
20
22
18
20
22
2
mm
0.82
0.52
0.32
0.82
0.52
0.32
0.82
0.52
0.32
1.31
0.82
0.52
0.32
0.22
0.82
0.52
0.32
0.82
0.52
0.32
0.82
0.52
0.32
0.82
0.52
0.32
PULL Force
Profile
Minimum
N
Lb.. 16-20 22-24
111.3 25.00
x
66.8 15.00
x
53.4 12.00
x
111.3 25.00
x
66.8 15.00
x
53.4 12.00
x
111.3 25.00
x
66.8 15.00
x
53.4 12.00
x
155.8 35.00
x
111.3 25.00
x
66.8 15.00
x
53.4 12.00
x
35.6 8.00
x
111.3 25.00
x
66.8 15.00
x
53.4 12.00
x
89.0 20.00
x
62.3 14.00
x
44.5 10.00
x
89.0 20.00
x
62.3 14.00
x
44.5 10.00
x
89.0 20.00
x
62.3 14.00
x
44.5 10.00
x
Locator
Order no.
Color
63819-1175
Red
63819-1175
Red
63819-1176
Yellow
63819-1175
Red
63819-1176 (yellow)
63819-1175
Red
63819-1175
Red
63819-1175
Red
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.
HANDLE WILL
SPRING OPEN
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.
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).
SQUEEZE
HANDLES
TOGETHER
Figure 1
Doc No: ATS-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 3 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning Crimp Terminals
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
Figure 3
TERMINAL
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.
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
WIRE AGAINST
THE WIRE
STOP
TERMINAL
Figure 4
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-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 4 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning 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
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 preformed to check hand tool crimp. Pull Force value Must exceed
the Minimum pull force specifications listed.
Locator Installation
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.
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
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-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 5 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning 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 locator 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
MATCH
UP MARKS
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:
Figure 9
FRONT
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
It is recommended that each operator of the tool be made aware of, and
responsible for, the following maintenance steps:
BACK
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
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.
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.
Doc No: ATS-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
RATCHET RELEASE
LEVER
Figure 11
Page 6 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning Crimp Terminals
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.
Doc No: ATS-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 7 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning 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-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 8 of 9
Hand Crimp Tool for 093” and Claspcon Pin and Socket and Commoning Crimp Terminals
PARTS LIST
Item Number
REF
1
1
2
3
Order Number
63819-1200
63819-1175
63819-1176
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
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-638191200
Revision: A
Release Date: 01-10-08
Revision Date: 01-10-08
UNCONTROLLED COPY
Page 9 of 9
