Hand Crimp Tool for SL Crimp Terminals
Order Number
200218-7000
Application Tooling Specification
TYPE 4D
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
Right- or left-handed operation
Easy handling due to outstanding force ratio
A precision user-friendly terminal locator with wire stop that holds terminals in the proper
crimping position
This tool is IPC/WHMA-A-620 compliant as indicated on page 3
Tooling can be installed in the 63816-1920 Power Crimp Head, which is installed into the 638160270 (110 V) or 63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp
Machine
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: SL Crimp Terminals, 24-30 AWG.
Terminal
Series No.
50083
50087
70021
70058
71851
Loose
50083-8100
50083-8114
50087-8100
50087-8114
16-02-0108
16-02-0109
16-02-0110
16-02-0096
16-02-0097
16-02-0098
16-02-0140
16-02-0151
16-02-1109
Terminal
Piece
50083-8160
50083-8170
50087-8130
50087-8160
16-02-0117
40-08-0872
70058-0096
70058-0097
70058-0098
70058-0140
70058-4096
16-02-1116
16-02-1117
Customer to cut off
Order No.
Wire Size ●Insulation Diameter
Strip Length
Reel
AWG
mm
In.
mm
In.
50083-8000 50083-8060
24-30
1.01-1.52 .040-.060 2.54-3.17 .100-.125
50083-8014 50083-8070
50087-8000 50087-8060
50087-8014 50087-8099
24-30
1.01-1.52 .040-.060 2.54-3.17 .100-.125
50087-8030
16-02-0077 16-02-0105
16-02-0078 40-08-0871
24-30
1.01-1.52 .040-.060 2.54-3.17 .100-.125
16-02-0091
16-02-0069 16-02-0150
16-02-0082 70058-0069
16-02-0083 70058-0082
24-30
1.01-1.52 .040-.060 2.54-3.17 .100-.125
16-02-0137 70058-0083
16-02-0139 70058-0139
70058-1069 70058-4069
16-02-1112 16-02-0119
24-30
1.01-1.52 .040-.060 2.54-3.17 .100-.125
16-02-1113 71851-0119
terminal from reel. See crimp specifications for desired terminal series.
CAUTION: Lubrication must be applied to the conductor punch to prevent terminal sticking.
Doc. No: 2002187000
Revision: C
Release Date: 11-23-20
Revision Date: 07-12-23
UNCONTROLLED COPY
Page 1 of 9
Hand Crimp Tool for SL Crimp Terminals
DEFINITION OF TERMS
CRIMP/TRANSITION
K
L
K
L
SECTION L-L
SECTION K-K
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed
in the scope.
CRIMP SPECIFICATIONS
The crimp specifications are as follows:
Feature
1. Bend Up
2. Bend Down
3. Twist
4. Roll
5. Bell Mouth Rear
6. Bell Mouth Front
7. Conductor Brush
8. Cut-Off Tab Rear
9. Cut-Off Tab Front
Conductor Crimp
Doc. No: 2002187000
Revision: C
Requirement
3° Max
3° Max
3° Max
8° Max
0.20-0.50mm (.008-.020”)
Not Applicable
0.00-1.00mm (.000-.039”)
For Terminal Series 50083 and 50087: 0.30mm (.012”) Max; for Terminal Series 70021:
0.13mm (.005”); for Terminal Series 70058 and 71851: 0.08mm (.003”) Max
For Terminal Series 50083 and 50087: 0.15mm (.006”) Max; for Terminal Series 70021,
70058 and 71851: 0.13mm (.005”) Max
Terminal Series No. Wire Size
10. Crimp Height
11. Crimp Width (Ref.)
24 AWG 0.79-0.87mm .031-.034 In.
1.05mm
.041 In.
26 AWG 0.74-0.81mm .029-.032 In.
1.05mm
.041 In.
50083
28 AWG 0-71-0.78mm .028-.031 In.
1.05mm
.041 In.
30 AWG 0-67-0.74mm .026-.029 In.
1.05mm
.041 In.
24 AWG 0.79-0.87mm .031-.034 In.
1.05mm
.041 In.
26 AWG 0.74-0.81mm .029-.032 In.
1.05mm
.041 In.
50087
28 AWG 0-71-0.78mm .028-.031 In.
1.05mm
.041 In.
30 AWG 0-67-0.74mm .026-.029 In.
1.05mm
.041 In.
24 AWG 0.79-0.84mm .031-.033 In.
1.05mm
.041 In.
26 AWG 0.74-0.79mm .029-.031 In.
1.05mm
.041 In.
70021
28 AWG 0-71-0.76mm .028-.030 In.
1.05mm
.041 In.
30 AWG 0-66-0.71mm .026-.028 In.
1.05mm
.041 In.
24 AWG 0.79-0.84mm .031-.033 In.
1.05mm
.041 In.
26 AWG 0.74-0.79mm .029-.031 In.
1.05mm
.041 In.
70058
28 AWG 0-71-0.76mm .028-.030 In.
1.05mm
.041 In.
30 AWG 0-66-0.71mm .026-.028 In.
1.05mm
.041 In.
24 AWG 0.79-0.84mm .031-.033 In.
1.05mm
.041 In.
26 AWG 0.74-0.79mm .029-.031 In.
1.05mm
.041 In.
71851
28 AWG 0-71-0.76mm .028-.030 In.
1.05mm
.041 In.
30 AWG 0-66-0.71mm .026-.028 In.
1.05mm
.041 In.
Release Date: 11-23-20
Revision Date: 07-12-23
UNCONTROLLED COPY
Page 2 of 9
Hand Crimp Tool for SL Crimp Terminals
Terminal Series No. Wire Size
24 AWG
26 AWG
50083
28 AWG
30 AWG
24 AWG
26 AWG
50087
28 AWG
30 AWG
24 AWG
26 AWG
70021
28 AWG
30 AWG
24 AWG
26 AWG
70058
28 AWG
30 AWG
24 AWG
26 AWG
71851
28 AWG
30 AWG
12. Crimp Height (Ref.)
1.60mm
.063 In.
1.58mm
.062 In.
1.55mm
.061 In.
1.55mm
.061 In.
1.60mm
.063 In.
1.58mm
.062 In.
1.55mm
.061 In.
1.55mm
.061 In.
1.60mm
.063 In.
1.58mm
.062 In.
1.55mm
.061 In.
1.55mm
.061 In.
1.60mm
.063 In.
1.58mm
.062 In.
1.55mm
.061 In.
1.55mm
.061 In.
1.60mm
.063 In.
1.58mm
.062 In.
1.55mm
.061 In.
1.55mm
.061 In.
13. Crimp Width (Ref.)
1.60mm
.063 In.
1.58mm
.062 In.
1.58mm
.062 In.
1.57mm
.062 In.
1.60mm
.063 In.
1.58mm
.062 In.
1.58mm
.062 In.
1.57mm
.062 In.
1.60mm
.063 In.
Insulation Crimp
1.58mm
.062 In.
1.58mm
.062 In.
1.57mm
.062 In.
1.60mm
.063 In.
1.58mm
.062 In.
1.58mm
.062 In.
1.57mm
.062 In.
1.60mm
.063 In.
1.58mm
.062 In.
1.58mm
.062 In.
1.57mm
.062 In.
Profile
Terminal Series No. Wire Size
Minimum Force
A
B
C
D
24 AWG
29.4 N
6.61 Lb.
X
26 AWG
19.6 N
4.41 Lb.
X
50083
28 AWG
9.8 N
2.20 Lb.
X
30 AWG
4.9 N
1.10 Lb.
X
24 AWG
29.4 N
6.61 Lb.
X
26 AWG
19.6 N
4.41 Lb.
X
50087
28 AWG
9.8 N
2.20 Lb.
X
30 AWG
4.9 N
1.10 Lb.
X
24 AWG
28.9 N
6.50 Lb.
X
Pull Force
26 AWG
17.8 N
4.00 Lb.
X
70021
28 AWG
11.1 N
2.50 Lb.
X
30 AWG
6.7 N
1.50 Lb.
X
24 AWG
28.9 N
6.50 Lb.
X
26 AWG
17.8 N
4.00 Lb.
X
70058
28 AWG
11.1 N
2.50 Lb.
X
30 AWG
6.7 N
1.50 Lb.
X
24 AWG
28.9 N
6.50 Lb.
X
26 AWG
17.8 N
4.00 Lb.
X
71851
28 AWG
11.1 N
2.50 Lb.
X
30 AWG
6.7 N
1.50 Lb.
X
To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:
Profile A: 1.10-1.25mm (.043-.049”) Profile B: 1.15-1.35mm (.045-.053”)
Profile C: 1.25-1.40mm (.049-.055”) Profile D: 1.10-1.30mm (.043-.051”)
Tool Qualification Notes
1. (Ref) means that the dimension provided is approximate because of the wide range of wires,
conductor stranding, insulation diameter and insulation hardness.
2. An occasional conductor crimp height measurement should be performed. It must lie between
the minimum and maximum crimp height specification.
3. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip
the wire long enough so the terminal’s insulation grips do not contact the wire insulation.
Doc. No: 2002187000
Revision: C
Release Date: 11-23-20
Revision Date: 07-12-23
UNCONTROLLED COPY
Page 3 of 9
Hand Crimp Tool for SL Crimp Terminals
Notes
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for AWG conductor sizes. It may not give good insulation crimp support for
insulation sizes outside of the specified range.
4. Molex does not repair hand tools. See warranty on page 8. The replacement parts listed are the
only parts available for repair. If the handles or crimp tooling become damaged or worn, a new
tool must be purchased.
5. Conductor crimp height should be used as the final criterion for an acceptable crimp. Refer to
Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
6. Molex does not certify hand crimp tools.
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 available, actual crimp height
measurements may vary slightly. An occasional destructive pull force test should be performed to
verify the conductor crimp. The pull force value must exceed the minimum pull force specifications
listed.
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 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.
Crimping Terminals
1. Select the desired terminal listed from the
preceding charts. Then, install it in the proper
locator. See chart above and see Locator
Replacement section 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.
LOCATOR PUSHED
THROUGH TOOLING
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOGETHER
Figure 2
PUSH ON THE
LOCATOR BUTTON
Figure 1
RELEASE
LOCATOR BUTTON
LOCATOR
LOCATOR
BUTTON
PUSHED
IN
TERMINAL
Doc. No: 2002187000
Revision: C
Figure 3
Release Date: 11-23-20
Revision Date: 07-12-23
TERMINAL
UNCONTROLLED COPY
Page 4 of 9
Hand Crimp Tool for SL Crimp Terminals
TOOLING
PARTIALLY
CLOSED
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.
WIRE AGAINST THE
WIRE STOP
WIRE STOP IS PART
OF THE LOCATOR
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
TERMINAL
PRE-STRIPPED
WIRE
FIRST RATCHET
POSITION
Figure 4
Figure 5
WIRE
TERMINAL
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been
completed. Release the handles to open the jaws.
Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.
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, and then close the
tool. See Figure 6.
WIRE
STOP
TERMINAL
Figure 6
Locator Replacement
LOCATOR
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 hand crimp 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 center of the locator down as far as
it will go as shown in Figure 7B.
SQUEEZE
HERE
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
SQUEEZE
HERE
Figure 7A
TOP SLOTS OF
HAND TOOL
TOP HOOKS
Figure 7B
LOWER TABS
Doc. No: 2002187000
Revision: C
Release Date: 11-23-20
Revision Date: 07-12-23
UNCONTROLLED COPY
Page 5 of 9
Hand Crimp Tool for SL Crimp Terminals
6. Holding onto the lower part of the locator with your thumb and index finger, insert the
locator’s top hooks into the hand tool’s 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-Handed 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:
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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
Figure 8
and replace the M3 BHCS. Make sure the
small markings on the front and back of
PUSH ON
the hand tool frame match up and are on
HANDLE
the outside of the hand tool frame. See
Figures 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.
MATCH
UP MARKS
Figure 9
FRONT
Doc. No: 2002187000
Revision: C
Release Date: 11-23-20
Revision Date: 07-12-23
BACK
UNCONTROLLED COPY
Page 6 of 9
Hand Crimp Tool for SL Crimp Terminals
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 a 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. See
Figure 10.
4. Wipe excess oil from the hand tool, particularly from the
crimping area. Oil transferred from the crimping area onto
certain terminations may affect the electrical characteristics of
an application.
5. When the 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT
OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
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 lifting upward on the ratchet release lever in the movable
handle. See Figure 11.
How to Adjust Tool Preload (See Figure 12)
Figure 11
Hand tool frame preload is factory preset to ensure crimp quality. 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. Open the hand tool.
SQUEEZE
HANDLE
HOLD THE
2. Close the handle 2 ratchet clicks.
THE
LINK
CLOSED
HAND
3. Hold the hand tool in the palm of
IN THE
2 CLICKS
TOOL IN
your hand as shown in Figure 12.
Using your index finger, squeeze
the link toward the top of the hand
tool frame. This will release the
preload adjustment wheel.
4. Rotate the setting wheel
counterclockwise to increase
handle force. The numbers will
display higher. To decrease handle
force, rotate the setting wheel
clockwise.
Figure
5. Release the link to lock the setting
12
SETTING
wheel in place.
WHEEL
6. Check the crimp specifications or conduct a pull test after tool handle preload force is
adjusted.
Doc. No: 2002187000
Revision: C
Release Date: 11-23-20
Revision Date: 07-12-23
UNCONTROLLED COPY
Page 7 of 9
Hand Crimp Tool for SL Crimp Terminals
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, Molex 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 use 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 or determine tool life:
If the tool does not meet minimum conductor crimp height, then the handle preload should be
increased, and the conductor crimp height re-evaluated. (See How to Adjust Preload). When
the hand tool is no longer capable of achieving minimum conductor crimp height, it should be
taken out of service and replaced.
The tool frame is very difficult to disassemble and reassemble. Customer repair is not
recommended.
Doc. No: 2002187000
Revision: C
Release Date: 11-23-20
Revision Date: 07-12-23
UNCONTROLLED COPY
Page 8 of 9
Hand Crimp Tool for SL Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
200218-7000
200218-7075
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
Application Tooling Support
E-Mail: toolingsupport@molex.com
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.
Doc. No: 2002187000
Revision: C
Release Date: 11-23-20
Revision Date: 07-12-23
UNCONTROLLED COPY
Page 9 of 9
