Hand Crimp Tool for 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp Terminal
HAND CRIMP TOOL
Specification Sheet
Order No. 63811-8600
TYPE 4D
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
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp Terminal, 20-22 AWG (AVSS and CAVS 0.500.30mm)
Terminal
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Series No. Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
50147
50147-8100 50147-8000 20-22 0.50-0.30 1.40-1.90 .055-.075 2.00-2.50 .079-.098
50148
50148-8100 50148-8000 20-22 0.50-0.30 1.40-1.90 .055-075 2.00-2.50 .079-.098
Follow the Cut-Off Tab specifications on Applicator specification sheets.
Æ
Æ
DEFINITION OF TERMS
BEND UP
BRUSH
BELL MOUTH
ROLLING
CONDUCTOR
CRIMP
INSULATION
CRIMP
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.
Doc No. ATS-638118600
Revision: A
Release Date: 07-16-07
Revision Date: 07-16-07
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool for 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp Terminal
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No
50147
50148
Wire Size
AWG
20
22
20
22
mm2
0.50
0.30
0.50
0.30
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
mm
In.
mm In.
mm
In.
mm In.
0.85-0.95 .033-.037 1.53 .060 1.69 .067 1.80 .071
0.85-0.95 .033-.037 1.47 .058 1.65 .065 1.77 .070
0.85-0.95 .033-.037 1.53 .060 1.69 .067 1.80 .071
0.85-0.95 .033-.037 1.47 .058 1.65 .065 1.77 .070
Pull Force
Profile
Minimum
N
Lb. 20 (0.5) 22 (0.3)
58.9 13.23
X
39.2 8.82
X
58.9 13.23
X
39.2 8.82
X
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.
LOCATOR IN
DOWN POSTION
HANDLE WILL
SPRING OPEN
Crimping Terminals
1. Select the desired terminal listed in the
preceding charts.
2. Make sure the center of the locator is
SQUEEZE
PUSH ON THE
in the down position. With the locator
HANDLES
Figure 2
LOCATOR BUTTON
TOGETHER
attached, push the locator button on
the back of the hand tool to bring the
Figure 1
locator 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
RELEASE
LOCATOR
BUTTON
TERMINAL
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Doc No. ATS-638118600
Revision: A
Release Date: 07-16-07
Revision Date: 07-16-07
Figure 3
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Hand Crimp Tool for 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp 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
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 4
WIRE AGAINST
THE WIRE STOP
WIRE STOP IS PART OF
THE LOCATOR
PRE-STRIPPED
WIRE
Figure 5
WIRE
TERMINAL
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.
WIRE
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.
Doc No. ATS-638118600
Revision: A
Release Date: 07-16-07
Revision Date: 07-16-07
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool for 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp Terminal
LOCATOR
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.
SQUEEZE
HERE
SQUEEZE
HERE
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.
TOP SLOTS OF
HANDTOOL
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP HOOKS
Figure 7B
Figure 7A
LOWER TABS
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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:
Figure 11
PUSH ON
HANDLE
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 11 and 12.
MATCH
UP MARKS
Figure 12
FRONT
Doc No. ATS-638118600
Revision: A
Release Date: 07-16-07
Revision Date: 07-16-07
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BACK
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Hand Crimp Tool for 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp Terminal
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 8
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 becoming lodged in the crimping dies,
and store the tool in a clean, dry area.
Miscrimps or Jams
RATCHET RELEASE
LEVER
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
9.
How to Adjust Tool Preload (See Figure 10)
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:
Figure 9
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 frame. This will release the preload adjustment wheel.
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.
Doc No. ATS-638118600
Revision: A
Release Date: 07-16-07
Revision Date: 07-16-07
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Page 5 of 7
Hand Crimp Tool for 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp Terminal
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.
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
Figure 10
SETTING
WHEEL
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-638118600
Revision: A
Release Date: 07-16-07
Revision Date: 07-16-07
UNCONTROLLED COPY
Page 6 of 7
Hand Crimp Tool for 2.50mm (.098”) Pitch Wire-to-Wire Splash Proof Crimp Terminal
PARTS LIST
Item Number
REF
1
2
3
Order Number
63811-8600
63811-8675
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
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
3
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-638118600
Revision: A
Release Date: 07-16-07
Revision Date: 07-16-07
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