Hand Crimp Tool For Quick Disconnect, Female Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63825-2800
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 as indicated
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: Quick Disconnect, Female, for 0.5, 0.8mm² & 1.0mm² and 18-20 AWG wire,
Terminal Series No.
94030
Wire Size
Terminal Order No.
Insulation Diameter
Maximum
mm
In.
Strip Length
mm²
AWG
mm
In.
94030-4020 94030-4021
0.50-1.00 18 - 20
2.60
.102
4.5 - 5.5 .177 -.217
94030-4530 94030-4531
● Customer to cut off terminal from reel. Cut tabs flush with terminal at both ends.
DEFINITION OF TERMS
STRIP
LENGTH
BELL MOUTH
WIRE
INSULATION
CRIMP
BRUSH
SEAM
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
TERMINAL
STRIP
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Doc No: ATS-638252800
Revision: A
Release Date: 09-12-12
Revision Date: 09-12-12
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool For Quick Disconnect, Female Terminals
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Conductor Crimp
Wire Size
Terminal
Series No
94030
AWG mm2
20
0.5
18
0.8
1.0
▲Insulation Crimp
Pull Force
Profile
Height (Ref.) Width (Ref.)
Minimum
Height
Width Maximum
Maximum
Maximum
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb. 18 20
1.30 – 1.40 .051-.055 2.30
.091
3.10 .122 3.50 .138 78.4 17.6
X
1.40 – 1.50 .055-.059 2.30
.091
3.15 .124 3.50 .138 117.6 26.4 X
1.45 – 1.55 .057-.061 2.30
.091
3.20 .126 3.50 .138 156.8 35.2 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.
OVERLAP FORM GEOMETRY
PUNCH
▲Insulation Crimp Note:
OVERLAP
INSULATION
CRIMP
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).
WIRE
ANVIL
LOCATOR
IN DOWN
POSTION
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.
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 2
PUSH ON THE
LOCATOR BUTTON
Crimping Terminals
1. Select the desired terminal listed in the
Figure 1
preceding charts.
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.
Doc No: ATS-638252800
Revision: A
Release Date: 09-12-12
Revision Date: 09-12-12
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool For Quick Disconnect, Female Terminals
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.
RELEASE
LOCATOR BUTTON
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
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.
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 4
TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE STOP IS PART
OF THE LOCATOR
WIRE
PRE-STRIPPED WIRE
Figure 5
TERMINAL
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Doc No: ATS-638252800
Revision: A
Release Date: 09-12-12
Revision Date: 09-12-12
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool For Quick Disconnect, Female 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 performed to check hand tool crimp. Pull
Force value Must exceed the Minimum pull force
specifications listed.
LOCATOR
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
Locator Replacement
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
TOP HOOKS
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.
Doc No: ATS-638252800
Revision: A
Release Date: 09-12-12
Revision Date: 09-12-12
Figure 7B
LOWER TABS
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
Figure 8
PUSH ON
HANDLE
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Hand Crimp Tool For Quick Disconnect, Female Terminals
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 if using the left handed application along with
the locator. Follow the steps below:
Figure 9
1. The locator must be removed before reversing the
BACK
FRONT
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:
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, lint free cloth.
2. Do not use any abrasive materials that could damage the tool.
Figure 10
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
RATCHET RELEASE
becoming lodged in the crimping dies, and store the tool in a clean, dry
LEVER
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.
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:
Doc No: ATS-638252800
Revision: A
Release Date: 09-12-12
Revision Date: 09-12-12
UNCONTROLLED COPY
Page 5 of 7
Hand Crimp Tool For Quick Disconnect, Female Terminals
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
SQUEEZE
HOLD THE HAND
frame. This will release the preload
THE LINK IN
RATCHET
TOOL IN POSITION
THE
HANDLE
adjustment wheel.
RELEASE LEVER
2. Rotate the setting wheel counterclockwise (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
Figure 12
preload force is adjusted.
Warranty
SETTING
WHEEL
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-638252800
Revision: A
Release Date: 09-12-12
Revision Date: 09-12-12
UNCONTROLLED COPY
Page 6 of 7
Hand Crimp Tool For Quick Disconnect, Female Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63825-2800
63825-2875
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
3
Figure 13
http://www.molex.com
Doc No: ATS-638252800
Revision: A
Release Date: 09-12-12
Revision Date: 09-12-12
UNCONTROLLED COPY
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