Hand Crimp Tool for 0.093, 0.125, MLX™, and Disk Drive Power Terminals
ServiceGrade®
Hand Crimp Tool
Application Tooling
Specification Sheet
Order No. 64016-0204
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 63811-3200,
63811-6800, 63811-7000, and/or 63811-7100
SCOPE
Products: See Charts Below.
OEM equivalent Hand Crimp Tool: 63811-3200 14-24 AWG
Products: 2.36mm (.093") Diameter, Standard .093" Pin and Socket Crimp Terminals, Commoning Connector Crimp Terminals,
Claspon™ Crimp Terminal Socket, and 3.18mm (.125") Diameter HCS-125 Pin and Socket Crimp Terminals.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Terminal
Series No.
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
02-09-1102 02-09-5111 39-00-0291
02-09-1104 39-00-0072 39-00-0294
1189
02-09-3102 39-00-0135 39-00-0295
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
02-09-3104 39-00-0288 50-29-1617
02-09-5106 39-00-0289
02-09-2103 02-09-6110 39-00-0299
02-09-4104 39-00-0106 39-00-0301
1190
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
02-09-6106 39-00-0297
02-09-2118 02-09-6126 39-00-0304
1380
02-09-2119 39-00-0302 39-00-0306
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
02-09-6123
02-09-1118 39-00-0307 39-00-0313
02-09-1119 39-00-0308 39-00-0314
1381
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
02-09-5133 39-00-0310 40-01-1191
02-09-5142
05-02-0048
05-02-0047
1457-1
05-02-0057
05-02-0056 18-22 0.82-0.32 1.55-2.59 .061-.102 3.30-3.80 .130-.150
05-02-0058
1457-2
05-02-0050
05-02-0049
14-16 2.08-0.82 3.56 Max. .140 Max. 3.30-3.80 .130-.150
1881-2
02-08-1102
16-24 1.31-0.32 3.51 Max. .138 Max. 3.30-3.80 .130-.150
1973
02-09-8104
18-22 0.82-0.32 3.51 Max. .138 Max. 3.30-3.80 .130-.150
1973-2
02-09-8109
14-18 2.08-1.31 4.06 Max. .160 Max. 3.30-3.80 .130-.150
2046
18-12-2222
16-18 2.08-1.31 3.05 Max. .120 Max. 3.30-3.80 .130-.150
2047
18-12-1222
16-18 2.08-1.31 3.05 Max. .120 Max. 3.30-3.80 .130-.150
2273
02-09-1123 02-09-1140
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
2282
18-09-2804 18-09-2807
14-18 2.08-0.82 3.56 Max. .140 Max. 3.60-4.10 .140-.160
4272
02-09-1149
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
Doc No: ATS-640160204
Revision: C
Release Date: 08-13-08
Revision Date: 01-18-11
UNCONTROLLED COPY
Page 1 of 5
Hand Crimp Tool for 0.093, 0.125, MLX™, and Disk Drive Power Terminals
OEM equivalent Hand Crimp Tool: 63811-3200 14-24 AWG
Products: 2.36mm (.093") Diameter, Standard .093" Pin and Socket Crimp Terminals, Commoning Connector Crimp Terminals,
Claspon™ Crimp Terminal Socket, and 3.18mm (.125") Diameter HCS-125 Pin and Socket Crimp Terminals.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Terminal
Series No.
Reel
Loose Piece
AWG
mm²
mm
In.
mm
In.
4549
02-09-2167
14-20 2.08-0.52 3.56 Max. .140 Max. 3.30-3.80 .130-.150
4550
02-09-1206 02-09-5170
14-20 2.08-0.52 3.56 Max .140 Max 3.30-3.80 .130-.150
6310
02-09-1211 02-09-5206
14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150
6271
02-09-1212
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
7238
02-09-1112
14-18 2.08-0.82 3.56 Max. .140 Max. 3.60-4.10 .140-.160
Customer to cut off terminal from reel using the Cut-off Tab dimension from the terminals selected.
OEM equivalent Hand Crimp Tool: 63811-6800
Products: MLX™ Pin and Socket Crimp Terminal 14 - 20 AWG.
Insulation
Terminal Order No.
Wire Size
Strip Length
Terminal
Diameter Maximum
Series No.
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
02-08-2004 02-08-2010 02-08-2003 02-08-2009
42023
02-08-2006 02-08-2012 02-08-2005 02-08-2011 14-20 2.00-0.50 1.52-3.30 .060-.130 3.96-5.53 .156-.218
02-08-2008
02-08-2007
02-08-1002 02-08-1006 02-08-1001 02-08-1005
42024
14-20 2.00-0.50 1.52-3.30 .060-.130 3.96-5.53 .156-.218
02-08-1004 02-08-1008 02-08-1003 02-08-1007
Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.
OEM equivalent Hand Crimp Tool: 63811-7000
Products: Disk Drive Power Connection System Crimp Terminal 14-20 AWG.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Terminal
Series No. Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
8980
02-08-1202 02-08-1201 14-20 2.00-0.50 3.56 Max. .140 Max. 4.75-5.54 .187-.218
Follow the Cut-Off Tab specifications on Applicator specification sheets.
These Terminals cannot be removed from the reel by manual cutting.
An applicator must be used or the terminals will not function properly.
OEM equivalent Hand Crimp Tool: 63811-7100
Products: .093” Pin and Socket 14-18 AWG and 24-30 AWG and Claspcon™ Crimp Terminal Socket 14-18 AWG.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Terminal
Series No. Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
42477
02-09-1615
14-18 2.00-0.80 2.36-3.55 .093-.140 3.96-5.53 .156-.218
42478
02-09-2612 02-09-2611 02-09-2613 14-18 2.00-0.80 2.36-3.55 .093-.140 3.96-5.53 .156-.218
Customer to cut off terminal from reel: 0.25mm (.010”) maximum Cut-off Tab.
Doc No: ATS-640160204
Revision: C
Release Date: 08-13-08
Revision Date: 01-18-11
UNCONTROLLED COPY
Page 2 of 5
Hand Crimp Tool for 0.093, 0.125, MLX™, and Disk Drive Power Terminals
CRIMPING INFORMATION:
Crimp the terminal and appropriate gauge wire in the specified profile.
Wire Size Pull Force Minimum ▼ Tool Crimp Profile
AWG mm²
N
Lb.
A
B
C
20 0.52
58
13
20 0.52
62
14
20 0.52
67
15
20 0.52
71
16
20 0.52
80
18
22 0.35
34
7.5
22 0.35
36
8
22 0.35
45
10
22 0.35
53
12
24 0.20
33
7.5
18 0.96
89
20
Terminal Series No
8058, 42023, 42024
2273, 4272, 6271
1189, 1190, 1380, 1381, 1457, 1881, 4549, 4550
8980
1973
1881
8058
2273, 4272, 6271
1380, 1381, 1457, 1973
1881
2273, 4272, 6271, 8058, 2023, 42024, 42477, 42478, 8980
1189, 1190, 1380, 1381, 1457, 1973,
18 0.96
111
2046, 2047, 2282, 4549, 4550, 7238, 42824, 42825
8980, 42023, 42024, 42477, 42478
133
16 1.23
1189, 1190, 1457, 1881, 1973,2046, 2047, 2282, 4549, 4550, 7238
155
1189, 1190, 1457, 1973, 2282, 4549, 4550, 7238
178
42023, 42024, 42477, 42478
14 1.94
222
8980
267
▼ Pull force test samples should not have the wire insulation crimped.
25
30
35
40
50
60
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 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
HAND TOOL
OPEN
Figure 1
CENTER CONDUCTOR GRIP OVER
THE CONDUCTOR ANVIL
Doc No: ATS-640160204
Revision: C
Release Date: 08-13-08
Revision Date: 01-18-11
CENTER INSULATION GRIP OVER
THE INSULATION
UNCONTROLLED COPY
Page 3 of 5
Hand Crimp Tool for 0.093, 0.125, MLX™, and Disk Drive Power Terminals
1. Select the desired terminal listed in the preceding charts.
2. Holding the terminal at the contact end, place the terminal on the
appropriate anvil. See Figure 1.
3. Slowly close the handles of the tool until the terminal is held in place.
If the handles are closed too far the terminal will begin to crimp.
4. 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. See Figure 2.
5. While holding the wire in place, slowly close the handles of the tool.
If a jam 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.
TERMINAL
WIRE
INSULATION
ANVIL
CONDUCTOR
ANVIL
Note: The illustration is a general representation. Some of the
terminals may look different and be held in a different area of the
terminal.
Figure 2
6. Continue to close the tool handles until the anti-backup ratchet
releases. Allow the handles to open.
7. Remove the crimped terminal from the tool.
8. Inspect the crimp for loose wire strands, missing crimp, or other
damage. Any minor terminal bending may be straightened by
hand.
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 2. If values do not exceed the minimum
pull force when all instructions are followed then a new tool is
required.
RATCHET
RELEASE
LEVER
LIFT UP
LEVER
Maintenance
Figure 3
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 4, 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 characteristics of an application.
Doc No: ATS-640160204
Revision: C
Release Date: 08-13-08
Revision Date: 01-18-11
Figure 4
UNCONTROLLED COPY
Page 4 of 5
Hand Crimp Tool for 0.093, 0.125, MLX™, and Disk Drive Power Terminals
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 3.
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.
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.
http://www.molex.com
Doc No: ATS-640160204
Revision: C
Release Date: 08-13-08
Revision Date: 01-18-11
UNCONTROLLED COPY
Page 5 of 5
