Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63827-0300
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 IPC/WHMA A-620 Class 2 compliant
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1.78mm (.070") Tab Female Crimp Terminals, 18-22 AWG.
Wire Size
Insulation Diameter
Strip Length
AWG
mm²
mm
In.
mm
In.
35028
35028-9010
18-22 0.80 - 0.35 2.00 - 2.90 .079 - .114 4.20 - 5.00
.165 -. 197
This Hand Tool provides optimum A-620 Class 2 crimps with insulation O.D. range of 2.30-2.90 mm.
Terminal Series No. Terminal Order No.
DEFINITION OF TERMS
BEND UP
STRIP LENGTH
ROLLING
BRUSH
BELL MOUTH
TWISTING
SEAM
BEND
DOWN
WIRE
CUT-OFF
TAB
CONDUCTOR
CRIMP HEIGHT
INSULATION
CRIMP HEIGHT
▲SEE NOTE
Doc No: ATS-638270300
Revision: B
Release Date: 06-19-13
Revision Date: 07-17-15
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals
▲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
WIRE
ANVIL
Terminal Series No.
35028
Terminal Series No.
Bell mouth
Mm
In.
0.20-0.50 .008-.020
Bend up Bend down Twist
Degree
35028
3
3
Cut-off Tab Maximum
mm
In.
0.20
.008
Roll
Degree
3
5
Conductor Brush
mm
In.
0.00-1.00 0.00-.039
Punch Width mm (Ref)
Seam
Conductor Insulation Seam shall not be open
mm In mm In and no wire allowed out
of the crimping area
2.10 .083 2.80 .110
After crimping, the conductor profiles should measure the following.
Terminal Series No.
35028
Terminal Series No.
35028
Conductor
Profile
Crimp Height
Crimp Width (Ref)
AWG mm2
mm
In.
mm
In.
20 18 22
18 0.80 1.27-1.37 .050-.054 2.10-2.20 .083-.087
X
20 0.50 1.15-1.25 .045-.049 2.10-2.20 .083-.087 X
22 0.35 1.07-1.17 .042-.046 2.10-2.20 .083-.087
X
Wire Size
Insulation (Ref)
Pull Force Minimum
Crimp Height Max.
Crimp Width
AWG mm2
mm
In.
mm
In.
N
Lb.
18 0.80
3.00
.118
2.85-2.95 .112-.116
88.9
20.0
20 0.50
2.70
.106
2.85-2.95 .112-.116
57.8
13.0
22 0.35
2.55
.100
2.85-2.95 .112-.116
35.6
8.0
Wire Size
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 Minimum pull force specifications listed.
OPERATION
HANDLE WILL
SPRING OPEN
SQUEEZE HANDLES
TOGETHER
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.
Doc No: ATS-638270300
Revision: B
Release Date: 06-19-13
Revision Date: 07-17-15
UNCONTROLLED COPY
Figure 1
Page 2 of 7
Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals
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.
LOCATOR
IN DOWN
POSTION
Crimping Terminals
PUSH ON
THE
LOCATOR
BUTTON
1. Select the desired terminal listed in the 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
Figure 2
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
LOCATOR
BUTTON
PUSHED IN
RELEASE
LOCATOR
BUTTON
LOCATOR
Figure 3
TERMINAL
TERMINAL
4.
5.
6.
7.
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.
WIRE AGAINST
THE
WIRE STOP
TERMINAL
WIRE STOP IS PART
OF THE LOCATOR
WIRE
Figure 5
TERMINAL
PRE-STRIPPED 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.
Doc No: ATS-638270300
Revision: B
Release Date: 06-19-13
Revision Date: 07-17-15
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals
WIRE
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
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.
TERMINAL
Figure 6
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
SQUEEZE
HERE
Figure 7A
JAWS OPEN
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOOLING
PULL OPEN
TOOLING
M3 BHCS
TOP SLOTS OF
HANDTOOL
TOP HOOKS
Figure 8
Figure 7B
PUSH ON
HANDLE
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.
4. To reinstall the new locator, make sure the hand
MATCH
tool is in the open position.
UP MARKS
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
Figure 9
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
BACK
FRONT
secure the locator into place, the lower tabs must
snap into place on the hand tool frame.
Doc No: ATS-638270300
Revision: B
Release Date: 06-19-13
Revision Date: 07-17-15
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals
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.
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.
3. Make certain all pins; pivot points and bearing surfaces are protected with a
Figure 10
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
RATCHET RELEASE
application.
LEVER
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.
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-638270300
Revision: B
Release Date: 06-19-13
Revision Date: 07-17-15
UNCONTROLLED COPY
Page 5 of 7
Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals
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 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
preload force is adjusted.
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
Figure 12
SETTING
WHEEL
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. 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-638270300
Revision: B
Release Date: 06-19-13
Revision Date: 07-17-15
UNCONTROLLED COPY
Page 6 of 7
Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63827-0300
63827-0375
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
Figure 13
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638270300
Revision: B
Release Date: 06-19-13
Revision Date: 07-17-15
UNCONTROLLED COPY
Page 7 of 7
