Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
Hand Crimp
Tool
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63819-1300
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, 18-24 AWG.
Terminal
Series No.
1560
1561
1786
1787
5005
5006
Terminal Order No.
Wire Size
Insulation Diameter
Loose Piece
Reel
AWG mm²
mm
In.
02-06-2103 02-06-6119 02-06-2101 02-06-6118
02-06-6102 04-01-0805 02-06-6100 39-00-0278
02-06-6103 39-00-0327 02-06-6101 39-00-0328 18-24 N/A 1.52-3.05 .060-.120
02-06-6104 39-00-0330 02-06-6105 39-00-0329
02-06-6112
02-06-6116
02-06-1103 04-01-0808 02-06-1101 04-01-0806
02-06-5102 39-00-0331 02-06-1118 39-00-0279
02-06-5103 39-00-0334 02-06-5100 39-00-0332 18-24 N/A 1.52-3.05 .060-.120
02-06-5104
02-06-5101 39-00-0333
02-06-5109
02-06-5108
02-06-2202 02-06-6202 02-06-2201 02-06-6201 18-24 N/A 1.52-3.05 .060-.120
02-06-1202
02-06-1201 02-06-5205
18-24 N/A 1.52-3.05 .060-.120
02-06-5201
08-70-0042 08-70-1012 08-70-0001 08-70-1011 18-24 N/A 1.30-3.00 .051-.118
08-70-0043 08-70-1014 08-70-0002 08-70-1013 18-24 N/A 1.30-3.00 .051-.118
Customer to cut off terminal from reel: 0.13mm (.005”) maximum Cut-off Tab.
Doc No: ATS-638191300
Revision: G
Release Date: 01-22-08
Revision Date: 05-05-16
UNCONTROLLED COPY
Strip Length
mm
In.
2.41-3.04 .095-.120
2.41-3.04 .095-.120
2.41-3.04 .095-.120
2.41-3.04 .095-.120
2.30-2.95 .090-.116
2.30-2.95 .090-.116
Page 1 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
DEFINITION OF TERMS
BRUSH
BEND UP
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION CRIMP
▲SEE NOTE
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.
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.
CRIMP SPECIFICATIONS
After crimping, the crimped terminals should measure as follows:
Terminal
Series No
1560
1561
1786
1787
5005
5006
Doc No: ATS-638191300
Revision: G
Wire Size
AWG mm2
18
20
N/A
22
24
18
20
N/A
22
24
18
20
N/A
22
24
18
20
N/A
22
24
18
20
N/A
22
24
18
20
N/A
22
24
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
mm
In.
mm
In.
mm
In.
mm
In.
0.87-0.97 .034-.038 1.66 .065 2.62 .103 2.47 .097
0.85-0.95 .033-.037 1.65 .065 2.60 .102 2.46 .096
0.82-0.92 .032-.036 1.50 .059 2.20 .087 2.23 .088
0.77-0.87 .030-.034 1.50 .059 2.12 .083 2.20 .087
0.87-0.97 .034-.038 1.66 .065 2.62 .103 2.47 .097
0.85-0.95 .033-.037 1.65 .065 2.60 .102 2.46 .096
0.82-0.92 .032-.036 1.50 .059 2.20 .087 2.23 .088
0.77-0.87 .030-.034 1.50 .059 2.12 .083 2.20 .087
0.87-0.97 .034-.038 1.66 .065 2.62 .103 2.47 .097
0.85-0.95 .033-.037 1.65 .065 2.60 .102 2.46 .096
0.82-0.92 .032-.036 1.50 .059 2.20 .087 2.23 .088
0.77-0.87 .030-.034 1.50 .059 2.12 .083 2.20 .087
0.87-0.97 .034-.038 1.66 .065 2.62 .103 2.47 .097
0.85-0.95 .033-.037 1.65 .065 2.60 .102 2.46 .096
0.82-0.92 .032-.036 1.50 .059 2.20 .087 2.23 .088
0.77-0.87 .030-.034 1.50 .059 2.12 .083 2.20 .087
0.94-1.04 .037-.041 1.68 .066 2.65 .104 2.54 1.00
0.91-1.01 .036-.040 1.67 .065 2.58 .102 2.48 .098
0.86-0.96 .034-.038 1.53 .060 2.27 .089 2.29 .090
0.84-0.94 .033-.037 1.52 .059 2.20 .079 2.22 .087
0.94-1.04 .037-.041 1.68 .066 2.65 .104 2.54 1.00
0.91-1.01 .036-.040 1.67 .065 2.58 .102 2.48 .098
0.86-0.96 .034-.038 1.53 .060 2.27 .089 2.29 .090
0.84-0.94 .033-.037 1.52 .059 2.20 .079 2.22 .087
Release Date: 01-22-08
Revision Date: 05-05-16
UNCONTROLLED COPY
Page 2 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
Note:
The crimp height chart is provided with this document as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and insulation hardness, actual crimp height measurements may very slightly. An
occasional, destructive, pull force test should be performed to check crimp integrity. Pull Force measurement must
exceed the minimum pull force specification.
Terminal Series No
1560
1561
1786
1787
5005
5006
Wire Size Pull Force Minimum
Profile
AWG mm2
N
Lb.
18-20 22-24
18 0.82
89
20
X
20 0.52
66.8
15
X
22 0.32
44.5
10
X
24 0.20
35.6
8
X
18 0.82
89
20
X
20 0.52
66.8
15
X
22 0.32
44.5
10
X
24 0.20
35.6
8
X
18 0.82
89
20
X
20 0.52
66.8
15
X
22 0.32
44.5
10
X
24 0.20
35.6
8
X
18 0.82
89
20
X
20 0.52
66.8
15
X
22 0.32
44.5
10
X
24 0.20
35.6
8
X
18 0.82
98
22
X
20 0.52
66.8
15
X
22 0.32
53.4
12
X
24 0.20
35.6
8
X
18 0.82
98
22
X
20 0.52
66.8
15
X
22 0.32
53.4
12
X
24 0.20
35.6
8
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.
▲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. While the
insulation punch profile may appear “lopsided”, this
is a normal condition for this tool. See figure below.
PUNCH
OVERLAP FORM GEOMETRY
OVERLAP
INSULATION
CRIMP
ANVIL
Doc No: ATS-638191300
Revision: G
Release Date: 01-22-08
Revision Date: 05-05-16
UNCONTROLLED COPY
WIRE
Page 3 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
Insulation Crimp Quality
Crimping small insulation diameter wire in the 22-24AWG profile may cause a buckled insulation crimp. This is
because the smaller insulation does not provide enough support to prevent the insulation grips from buckling while
they are trying to overlap form.
The buckled insulation crimp can be prevented by using a larger insulation diameter wire. For example, the
insulation crimps shown below are on a 24AWG wire. The UL1007 insulation does not provide enough support and
the insulation grips buckle. The larger UL1015 insulation provides better grip support and the grips overlap.
24AWG UL1007: GRIPS BUCKLE
24AWG UL1015: GRIPS OVERLAP
In general, buckling can be prevented in the 22-24AWG profile by using an insulation diameter that is at least
1.6mm (0.063 in).
If small insulation diameter must be used, insulation grip buckling is acceptable
provided that the insulation crimp does not damage the wire’s conductor and the
crimped terminal fits into the connector housing.
HANDLE WILL
SPRING OPEN
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.
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.
SQUEEZE
HANDLES
TOGETHER
Figure 1
Crimping Terminals
1. Select the desired terminal from the chart, and install the proper locator (See chart above and 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.
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.
Doc No: ATS-638191300
Revision: G
Release Date: 01-22-08
Revision Date: 05-05-16
UNCONTROLLED COPY
Page 4 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
LOCATOR IN
DOWN POSTION
TERMINAL
LOCATOR
PUSHED THRU
TOOLING
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
Figure 2
PUSH ON THE
LOCATOR BUTTON
Figure 3
TERMINAL
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.
TERMINAL
PRE-STRIPPED
WIRE
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
WIREFIRST
STOPRATCHET
IS
PART OFPOSITION
THE
LOCATOR
Figure 4
WIRE AGAINST
THE WIRE
STOP
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.
Doc No: ATS-638191300
Revision: G
Release Date: 01-22-08
Revision Date: 05-05-16
TERMINAL
UNCONTROLLED COPY
Page 5 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
Locator Replacement
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
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
SQUEEZE
HERE
JAWS OPEN
TOOLING
PULL OPEN
TOOLING
M3 BHCS
TOP HOOKS
Figure 8
PUSH ON
HANDLE
Figure 7B
Figure 7A
LOWER TABS
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 (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 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 screw that holds the upper
tooling.
Doc No: ATS-638191300
Revision: G
Release Date: 01-22-08
Revision Date: 05-05-16
MATCH
UP MARKS
Figure 9
FRONT
UNCONTROLLED COPY
BACK
Page 6 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
3. Flip the upper tooling to the opposite side and replace the M3 screw. 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. Reverse the lower tooling and tighten the M3 screw. 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:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
1. Remove dust, moisture, and other contaminants with a clean brush, or soft,
Figure 10
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
RATCHET RELEASE
transferred from the crimping area onto certain terminations may affect the
LEVER
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
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
pounds. 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 12. Using
the index finger squeeze the link
towards the top of the hand tool
frame. This will release the preload
adjustment wheel.
Doc No: ATS-638191300
Revision: G
RATCHET
RELEASE LEVER
Figure 11
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
Figure 12
SETTING
WHEEL
Release Date: 01-22-08
Revision Date: 05-05-16
UNCONTROLLED COPY
Page 7 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
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.
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-638191300
Revision: G
Release Date: 01-22-08
Revision Date: 05-05-16
UNCONTROLLED COPY
Page 8 of 9
Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63819-1300
63819-1375
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
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638191300
Revision: G
Release Date: 01-22-08
Revision Date: 05-05-16
UNCONTROLLED COPY
Page 9 of 9
