Hand Crimp Tool for 0.156” KK™ and 0.062” Terminals
ServiceGrade™ Hand Crimp Tool
Specification Sheet
Order No. 64016-0205
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
For crimps conforming to WHMA-IPCA620 Class 2, use hand crimp tools 11-010185, 63811-3300, and/or 63811-7500.
SCOPE
Products: 0.156” KK™ and 0.062” pin and socket terminals, 18-30 AWG
0.062” Terminals
(WHMA-IPCA620 equivalent hand tool: 63811-3300)
Terminal
Terminal Order No.
Wire Size
Insulation Diameter
Series No.
Loose Piece
Reel
AWG
mm²
mm
In.
02-06-2103 02-06-6119 02-06-2101 02-06-6118
02-06-6102 39-00-0327 02-06-6100 39-00-0278
1560
18-24 0.82-0.20 1.52-3.05 .060-.120
02-06-6103 39-00-0330 02-06-6101 39-00-0329
02-06-6104
02-06-1103 02-06-5109 02-06-1101 02-06-5105
02-06-5102 39-00-0331 02-06-1118 02-06-5108
1561
18-24 0.82-0.20 1.52-3.05 .060-.120
02-06-5103 39-00-0334 02-06-5100 39-00-0279
02-06-5104
02-06-5101 39-00-0333
02-06-2202
02-06-2201
1786
18-24 0.82-0.20 1.52-3.05 .060-.120
02-06-6202
02-06-6201
1787
02-06-1202
02-06-1201 02-06-5201 18-24 0.82-0.20 1.52-3.05 .060-.120
08-30-0110 08-34-0108 08-30-0109 08-35-0105
1799
18-24 0.82-0.20 1.52-3.05 .060-.120
08-34-0106 08-35-0106 08-34-0105
4529
02-06-1105 02-06-5208 02-06-1104 02-06-5207 18-24 0.82-0.20 1.52-3.05 .060-.120
5005
08-70-0042
08-70-0001
18-24 0.82-0.20 1.30-3.00 .051-.118
5006
08-70-0043
08-70-0002
18-24 0.82-0.20 1.30-3.00 .051-.118
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
2.41-3.04 .095-.120
2.41-3.04 .095-.120
2.30-2.95 .090-.116
2.30-2.95 .090-.116
0.062” Terminals
(WHMA-IPCA620 equivalent hand tool: 11-01-0185)
Terminal
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Series No.
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
02-06-2132 02-06-6144 02-06-2131 02-06-6143
02-06-6135 04-01-0811 02-06-6130 04-01-0809
1854
24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
02-06-6136 39-00-0335 02-06-6137 39-00-0280
02-06-6139 39-00-0337 02-06-6138 39-00-0336
02-06-1132 02-06-5148 02-06-1131 02-06-5147
02-06-5135 04-01-0812 02-06-1141 04-01-0810
1855
02-06-5139 39-00-0339 02-06-1143 39-00-0338 24-30 0.20-0.05 1.02-2.29 .040-.090 3.17-3.96 .125-.156
39-00-0341 02-06-5130 39-00-0340
02-06-5138
Doc No: ATS-640160205
Revision: B
Release Date: 06-03-08
Revision Date: 06-03-08
UNCONTROLLED COPY
Page 1 of 6
Hand Crimp Tool for 0.156” KK™ and 0.062” Terminals
0.156” KK™
(WHMA-IPCA620 equivalent hand tool: 63811-7500)
Terminal
Terminal Order No
Wire Size
Insulation Diameter
Series No
Loose Piece
Reel
AWG
mm²
mm
In.
2477
08-50-0110 08-56-0114 08-50-0109 08-56-0113 18-24 0.80-0.20 1.39-2.79 .055-.110
08-50-0006 08-55-0134 08-50-0001 08-52-0073
08-50-0016 08-56-0106 08-50-0014 08-52-0114
08-50-0045 08-56-0154 08-50-0015 08-52-0811
08-50-0046 08-58-0104 08-50-0047 08-53-0004
08-50-0056 08-58-0115 08-50-0055 08-53-0811
08-50-0064 08-58-0122 08-50-0063 08-55-0103
08-50-0074 08-65-0115 08-50-0073 08-55-0133
08-50-0093 39-00-0342 08-50-0091 08-56-0105
08-50-0106 39-00-0344 08-50-0105 08-56-0153
08-50-0120 39-00-0348 08-50-0119 08-58-0103
2478
18-24 0.80-0.20 1.39-2.79 .055-.110
08-50-0147 39-00-0350 08-50-0146 08-58-0114
08-52-0024 40-01-1120 08-50-0271 08-58-0121
08-52-0045 50-29-1762 08-50-0281 08-65-0114
08-52-0047 50-30-4428 08-51-0001 39-00-0286
08-52-0072 50-30-4429 08-51-0720 39-00-0343
08-52-0074
08-52-0023 39-00-0347
08-52-0115
08-52-0027 39-00-0349
08-52-0812
08-52-0044 40-01-1118
08-53-0812
08-52-0046 50-29-1689
08-52-0071 50-29-1768
08-55-0104
08-50-0116 08-58-0128 08-50-0115 08-55-0138
08-52-0127 08-65-0119 08-51-0109 08-58-0127 18-20 0.80-0.50 1.52-2.79 .060-.110
2878
08-52-0126 08-65-0118
08-53-0814
08-50-0132 08-55-0143 08-50-0131 08-55-0142
4838
08-55-0140 08-55-0146 08-55-0125 08-55-0145 18-22 0.80-0.35 1.52-2.41 .060-.095
08-55-0141 08-55-0148 08-55-0139 08-55-0147
08-70-0013 08-70-1034 08-70-0012
5167
18-24 0.80-0.20 1.39-2.48 .055-.098
08-70-0097
08-50-0165 08-56-0139 08-50-0164 08-56-0135
6438
08-51-0802 08-58-0189 08-51-0801 08-56-0137 18-20 0.80-0.50 1.52-2.41 .060-.095
08-56-0133
08-53-0813
08-50-0029 08-58-0119 08-50-0024 08-58-0105
08-50-0189 08-58-0132 08-50-0026 08-58-0108
08-50-0251 08-60-0002 08-50-0028 08-58-0110
08-51-0107 50-29-1763 08-50-0187 08-58-0118
6838
08-52-0113 50-29-1879 08-50-0275 08-58-0131 18-20 0.80-0.50 1.52-2.79 .060-.110
08-53-1102
08-51-0106 08-58-0187
08-58-0106
08-52-0112 08-60-0001
08-58-0109
08-53-1101 50-29-1639
08-58-0111
08-58-0102
08-50-0023 08-58-0136 08-50-0008 08-58-0135
08-50-0706 08-65-0129 08-50-0705 08-65-0128
8818
18 - 22 0.80-0.35 1.52-2.79 .060-.110
08-52-0132
08-52-0131 40-01-1181
08-56-0188
08-56-0187 40-01-1182
8993
08-50-0276
08-50-0011 08-50-0277 18-24 0.80-0.20 1.39-2.79 .055-.110
Doc No: ATS-640160205
Revision: B
Release Date: 06-03-08
Revision Date: 06-03-08
UNCONTROLLED COPY
Strip Length
mm
In.
2.54-3.17 .100-.125
2.54-3.17 .100-.125
2.54-3.17 .100-.125
2.54-3.17 .100-.125
2.54-3.17 .100-.125
2.54-3.17 .100-.125
2.54-3.17 .100-.125
2.54-3.17 .100-.125
2.54-3.17 .100-.125
Page 2 of 6
Hand Crimp Tool for 0.156” KK™ and 0.062” Terminals
Crimping Information:
Crimp the terminal and appropriate gauge wire in the specified profile.
Terminal Series No
Wire Size
Pull Force Min.
▼
Tool Crimp Profile
AWG
mm2
N
Lb.
A
24
0.20
35.6
8.0
26
0.12
22.2
5.0
1854, 1855
28
0.08
13.3
3.0
30
0.05
8.9
2.0
18
0.82
89
20
1560, 1561, 1786, 1787,
20
0.52
58
13
4529, 5005, 5006
22
0.32
35.6
8
24
0.20
22
5
18
0.82
89
20
1799, 2478, 2878, 4838, 5167,
20
0.52
58
13
6438, 6838, 8818, 8993
22
0.32
35.6
8
24
0.20
28.9
6.5
Pull force test samples should not have the wire insulation crimped.
B
C
▼
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.
Remove the terminal holder from the tool and set it aside.
Open the hand tool by squeezing the handles together; at the end of the closing stroke the anti-backup ratchet will
release. Release the handles and the hand tool will open.
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
2. Open the terminal holder by pressing down the lever and place the terminal in the holder.
PRESS DOWN
LEVER TO OPEN
INSULATION GRIP
TERMINAL HOLDER
CLOSED ON TERMINAL
TERMINAL HOLDER
TERMINAL CENTERED
IN TOOL HOLDER
Figure 1
CONDUCTOR
GRIP
Note: The above illustration is a general representation. Some of the terminals may look different and be held in a
different area of the terminal.
Doc No: ATS-640160205
Revision: B
Release Date: 06-03-08
Revision Date: 06-03-08
UNCONTROLLED COPY
Page 3 of 6
Hand Crimp Tool for 0.156” KK™ and 0.062” Terminals
3. Release the lever to hold the terminal in place. See Figure 1.
4. Carefully place the terminal holder on the shelf of the hand tool and center the terminal as shown over the
appropriate tool crimp profile. See Figure 2.
Note: Some terminals may have a large insulation grip; extra care should be taken when loading these
terminals into the tool to avoid terminal damage.
CENTER CONDUCTOR
GRIP OVER THE
CONDUCTOR ANVIL
TERMINAL
HOLDER
WIRE
SHELF OF
HAND TOOL
SHELF OF
HAND TOOL
CENTER TERMINAL OVER
CRIMP PROFILE
Figure 2
5. Place a pre-stripped wire into the terminal (see Scope chart for
recommended strip lengths). Position the wire so the
conductor lies in the conductor grip.
6. While holding the wire in place, slowly close the handles of the
tool. If excessive resistance is felt, there may be a jam. If this
occurs, stop closing the tool and release the anti-backup
ratchet by lifting up the lever near the top of the moving handle.
See figure 3.
7. Continue to close the tool handles until the anti-backup ratchet
releases. Allow the handles to open.
8. Remove the crimped terminal and terminal holder from the tool.
9. Press down the lever on the terminal holder and remove the
crimped terminal.
10. Inspect the crimp for loose wire strands, missing crimp, or
other damage. Any minor terminal bending may be
straightened by hand.
Doc No: ATS-640160205
Revision: B
Release Date: 06-03-08
Revision Date: 06-03-08
CONDUCTOR ANVIL
RATCHET
RELEASE
LEVER
LIFT UP
LEVER
UNCONTROLLED COPY
Figure 3
Page 4 of 6
Hand Crimp Tool for 0.156” KK™ and 0.062” Terminals
Note:
An occasional, destructive, pull force test with the terminal and wire crimped should be performed to check hand
tool crimp. The pull force value must exceed the terminal’s minimum pull force specifications listed on page 3. If
values do not exceed the minimum pull force when all instructions are followed then a new tool is required.
Maintenance
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. Light oil (such as
SAE30W oil) applied at the oil points, shown in Figure
3, every 5,000 crimps or 3 months, is recommended.
4. Wipe excess oil from hand tool, particularly from
crimping area. Oil transferred from the crimping area
onto certain terminations may affect the electrical
Figure 3
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
If the tool ever becomes jammed in a partially closed position, DO NOT force the handles open or closed. The tool
will open by lifting the ratchet release lever. See Figure 2.
Tool Handle Preload
Tool handle preload cannot be adjusted.
This hand tool is set to a preload that will fully close the tool jaws without excessive force from the operator. Over
the life of the tool the tool linkage can wear and handle preload force may decrease. It is the operator’s
responsibility to periodically perform a tensile pull test on the crimped wire. If the pull test value falls below
specification, the tool should be replaced.
Doc No: ATS-640160205
Revision: B
Release Date: 06-03-08
Revision Date: 06-03-08
UNCONTROLLED COPY
Page 5 of 6
Hand Crimp Tool for 0.156” KK™ and 0.062” Terminals
Warranty
This tool is for electrical terminal crimping purposes only. All tools are warranted to be free of manufacturing
defects for a period of 30 days. Should such a defect occur, the tool will be exchanged free of charge. This
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. NEVER perform crimps on active
electrical circuits.
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 ServiceGrade™ hand tools but rather supplies the following guidelines for
customers to maintain their 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.
% When the hand tool is no longer capable of achieving minimum pull force, it should be replaced.
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
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-640160205
Revision: B
Release Date: 06-03-08
Revision Date: 06-03-08
UNCONTROLLED COPY
Page 6 of 6
