Hand Crimp Tool for 093” and Claspcon Pin and S ocket and Comm oni ng Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N T ROLLED CO P Y Page 1 of 9
Revision: A Revision Date: 01-10-08
HAND CRIMP TOOL
Specificat ion Sheet
Order No. 63819- 1200
FEATURES
A f ul l cycl e ratcheting hand tool ensures compl ete crimps
Ergonomi c soft gri p handl es f or comfortable crim pi ng
A precision user-f ri endly t erm i nal l ocat or wi re st op hol ds t erm i nal s in the proper crimping posit i on
Right and Left handed appli cat ions
This tool i s WHMA-IP CA 620 Cl ass 2 compliant as indicated
This tool is RoHS com pl i ant , however RoHS compli ant i s not requi red
SCOPE
Products: 2.36mm (. 093") Di am eter, S t andard .093" Pin and Socket Crimp Term i nals, 18-22 AWG,
Claspcon Pin and S ocket Cri m p Term inal s, 16-24 A WG, and Commoning Term i nal s, 18-22 A WG.
Term inal Order No. Wire Si ze
Æ
Insul ation D i am eter Strip Length
Terminal
Series No. Loose Piece + Reel AWG mm² mm In. mm In.
02-09-2118 02-09-6126
1380 02-09-6123 39-00-0302 18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
02-09-1118 39-00-0307
02-09-1119 39-00-0308
02-09-5133
1381
02-09-5142
18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
1457-1 05-02-0048 05-02-0047 18-22 0.82-0.32 1.55-2.59 .061-.102 3.30-3.80 .130-.150
1881-2 02-08-1102 16-24 1.31-0.22
Æ
1.50-3.50 .059-.138 3.30-3.80 .130-.150
1973 02-09-8104 18-22 0.82-0.32
Æ
3.51 M ax. .138 M ax. 3.30-3. 80 .130-.150
2273 02-09-1123 18-22 0.82-0.32 1.52-3.05 .060-.120 3.30-3.80 .130-.150
4272 02-09-1149 18-22 0.82-0.32 1.52-3.05 .060-.120 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
+ Customer to cut off terminal from reel: 0.18mm (.007”) maximum Cut-off Tab.
Æ
To Achieve I PC -A-620 Cl ass 2 Cri m ps, the foll o wing wire insul ation diameter limits are recomm ended:
1. Terminal #1881-2 m axi m um di am eter - 3.14mm (.124 i nch)
2. Terminal #1973 m axi mum diam et er - 2.85m m (. 112 i nch)
3. 16 - 20 AWG Profile mi ni m um di am et er (all terminals) - 1.70m m (.067 i nch)
TYPE 4D
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 2 of 9
Revision: A Revision Date: 01-10-08
DEFINITION OF TERMS
The above termi nal drawi ng i s a generic t erm i nal represent ation. It is not an im age of a termi nal l ist ed i n the scope.
CONDITIONS:
Af t e r crimpi ng, the conductor prof i l es should measure t he following.
Wire Size Conductor Crim p Insulation Crim p
Terminal Series No AWG mm2 Height ( Ref.) Widt h (Ref .) Height (Ref.) Width (Ref.)
18 0.82 1.48 – 1. 58 .058-.062 1.93 .076 2.88 .113 2. 59 .102
20 0.52 1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1380 22 0.32 1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
18 0.82 1.48 – 1. 58 .058-.062 1.93 .076 2.88 .113 2. 59 .102
20 0.52 1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1381 22 0.32 1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
18 0.82 1.48 – 1. 58 .058-.062 1.93 .076 2.88 .113 2. 59 .102
20 0.52 1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1457-1 22 0.32 1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
16 1.31 1.52 – 1.62 .060-.064 1.95 .077 2.96 .117 2.63 .104
18 0.82 1.48 – 1. 58 .058-.062 1.93 .076 2.88 .113 2. 59 .102
20 0.52 1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
22 0.32 1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
1881-2
24 0.22 1.27 – 1.37 .050-.054 1.90 .075 2.30 .091 2.28 .090
18 0.82 1.48 – 1. 58 .058-.062 1.93 .076 2.88 .113 2. 59 .102
20 0.52 1.37 – 1.47 .054-.058 1.92 .076 2.70 .106 2.56 .101
1973 22 0.32 1.34 – 1.44 .053-.056 1.91 .075 2.44 .096 2.31 .091
18 0.82 1.37 – 1.47 .054-.058 1.92 .076 2.75 .108 2.58 .102
20 0.52 1.27 – 1.37 .050-.054 1.90 .075 2.63 .104 2.48 .098
2273 22 0.32 1.25 – 1.35 .049-.053 1.88 .074 2.35 .093 2.30 .091
18 0.82 1.37 – 1.47 .054-.058 1.92 .076 2.75 .108 2.58 .102
20 0.52 1.27 – 1.37 .050-.054 1.90 .075 2.63 .104 2.48 .098
4272 22 0.32 1.25 – 1.35 .049-.053 1.88 .074 2.35 .093 2.30 .091
18 0.82 1.37 – 1.47 .054-.058 1.90 .076 2.75 .108 2.58 .102
20 0.52 1.27 – 1.37 .050-.054 1.90 .075 2.63 .104 2.48 .098
6271 22 0.32 1.25 – 1.35 ..049-.053 1.88 .074 2.35 .093 2.30 .091
INSULATIO N
CRIMP
BRUSH
STRIP
LENGTH
BELL M OUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 3 of 9
Revision: A Revision Date: 01-10-08
Wire Size PULL Force
Minimum Profile Locator
Terminal Series No AWG mm2 N Lb.. 16-20 22-24 Order no. Color
18 0.82 111.3 25.00 x
20 0.52 66.8 15.00 x
1380 22 0.32 53.4 12.00 x 63819-1175 Red
18 0.82 111.3 25.00 x
20 0.52 66.8 15.00 x
1381 22 0.32 53.4 12.00 x 63819-1175 Red
18 0.82 111.3 25.00 x
20 0.52 66.8 15.00 x
1457-1 22 0.32 53.4 12.00 x 63819-1176 Yellow
16 1.31 155.8 35.00 x
18 0.82 111.3 25.00 x
20 0.52 66.8 15.00 x
22 0.32 53.4 12.00 x
1881-2
24 0.22 35.6 8.00 x
63819-1175 Red
18 0.82 111.3 25.00 x
20 0.52 66.8 15.00 x
1973 22 0.32 53.4 12.00 x 63819-1176 (yellow)
18 0.82 89.0 20.00 x
20 0.52 62.3 14.00 x
2273 22 0.32 44.5 10.00 x 63819-1175 Red
18 0.82 89.0 20.00 x
20 0.52 62.3 14.00 x
4272 22 0.32 44.5 10.00 x 63819-1175 Red
18 0.82 89.0 20.00 x
20 0.52 62.3 14.00 x
6271 22 0.32 44.5 10.00 x 63819-1175 Red
OPERATION
CAUTION: I nst al l onl y Mol ex t erm i nals li st ed above with this t ool . Do not crimp
hardened objects as damage can occur to the tool or die.
Open the t ool by squeezing the handles t ogether. At the end of t he closing
stroke, the ratchet mechanism will release the handles and the hand tool will
spring open. S ee Fi gure 1.
Crimping Terminals
1. Sel ect the desired termi nal li st ed from the preceding charts, and i nst al l the
proper locator (S ee chart above and see Locator I nst al l at i on on page 5).
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 4 of 9
Revision: A Revision Date: 01-10-08
Figure 5
TERMINAL
WIRE AGAI NST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF THE
LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
LOCATOR IN
DOWN POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
2. Make sure the cent er of the locator is in the down position. With the locator at tached, push the locat or button
on the back of t he hand tool to bring the locator f orward through the tool i ng. See Figure 2.
3. While hol di ng i n t he l ocat or button, load the termi nal i nt o the proper
nest opening in the locator based on t he wire gauge or terminal type
markings on the hand t ool i ng. S ee Fi gure 3.
4. Release the l ocat or button, al lo wing the locator t o ret urn to the crimpi ng
position.
5. Close the tool handle unti l the first rat chet position engages. See
Figure 4.
6. Insert the properly stripped wire through the t erm i nal and agai nst the
wire stop. S ee Fi gure 5.
7. Crimp the termi nal by squeezing the t ool handl es unt i l the ratchet
mechanism cycl e has been com pl eted. Rel ease t he handl es to open
the j aws.
Note: The t amper proof ratchet acti on will not release the t ool until it has been fully closed.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 5 of 9
Revision: A Revision Date: 01-10-08
8. Remove the crim ped terminal from the terminal
locator by pull i ng on the wire.
9. Vi suall y inspect the crimped term i nal f o r proper
crimp locati on.
10. On some large O. D. wi res, i t m a y not be possibl e
to i nsert t he wi re wi th the t ool partially closed.
Those wires should be inserted with the hand t ool
in the open position. Insert the wi re above t he
termi nal i n the punch and against the wi re st op
then close the t ool . See Figure 6.
Note:
A crimp hei ght chart i s provided with this m anual as Ref erence Only. Due to the wide range of wires, st rands,
insulati on di am et ers, and durom eters available, act ual crimp hei ght measurements may very slight ly. An
occasional, destructi ve, pull force test should be pref orm ed t o check hand tool crim p. Pull Force value Must exceed
the Mi ni m um pul l force specifications li st ed.
Locator Installation
See t he part s l ist on the last page of this document f or the proper locator order number. Follow t he st eps below t o
replace the lo cat or.
1. Open the crimp hand tool.
2. Squeeze gent ly on t he l ower area shown in Fi gure 7A with your t hum b and index f i nger. The lower tabs of t he
locator should disengage f rom t he hand tool.
3. Lif t and pul l away from t he hand tool. The t op l ocat or hooks should slip out of the top slot s easily. See Figure
7A.
TERMINAL
Figure 6
WIRE
WIRE STOP
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M 3 BHCS
SQUEEZE
HERE
LOCATOR
Figure 7A
SQUEEZE
HERE
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
M AKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITI ON
Figure 7B
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 6 of 9
Revision: A Revision Date: 01-10-08
4. To reinstal l t he new l ocat or, m ake sure t he hand t ool i s in t he 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 t he l ocat or wi th your thumb and index f i nger, insert t he l ocat o r t op hooks (2) int o
the hand t ool t op slots.
7. Rotate the locat or down and press the l ower t abs into the t wo bot tom slots of the hand tool. To secure the
locator into place, t he l ower t abs m ust snap i nt o pl ace on t he hand t ool frame.
Right or Left Hand Operation
This hand tool has an added f eat ure that can be
converted from a ri ght handed appl i cat i on t o a l eft
handed applicati on. It i s necessary to reverse the
tooli ng al ong wi t h the locator if using the left handed
applicati on. Follow t he steps below:
1. The locator m ust be rem oved bef ore reversing t he
tooling.
2. Remove t he M3 B HCS whi ch is hol di ng t he upper tooling.
3. Flip the upper tooling to the opposit e side and repl ace t he M 3 B HCS
Make sure the small m arkings on the front and back of t he hand t ool
frame m at ch up and are on t he outside of t he hand t ool f ram e. See
Figure 8 and 9.
4. Do the same t hi ng wi t h t he l ower tooling and t i ght en the M3 screws.
Be sure the sm all m arkings li ne up.
5. Reinstal l the locator by f ol l owi ng t he Instructi ons in t he l ocator
replacement secti on.
Maintenance
It i s recommended that each operator of the tool be m ade aware of, and
responsible for, the f ol lo wing m ai ntenance steps:
1. Remove dust, m oi st ure, and other contam i nant s wi t h a clean brush, or soft, lint free cloth.
2. Do not use any abrasive materi al s t hat could dam age the tool.
3. Make certai n all pi ns; pi vot poi nt s and bearing surf aces are prot ected wi th
a thin coat of hi gh qual i t y machine oi l . Do not oil excessively. The tool
was engineered for durability but like any other equipment it needs
cleaning and lubricat i on for a maximum service li f e of trouble f ree
crimping. Li ght oi l (such as 30 weight aut om otive oil) used at t he oi l
points, every 5,000 crimps or 3 months, will significantly enhance the tool
life.
4. Wipe excess oil from hand tool, part i cularl y f rom crimpi ng area. Oil
transferred from the crimpi ng area onto certain t erm i nat i ons may af fect
the elect ri cal characteri sti cs of an appl i cat i on.
5. When tool is not i n use, keep t he handles closed to prevent obj ect s from
becoming lodged in the crimping dies, and st ore t he tool in a clean, dry area.
RATCHET RELEASE
LEVER
Figure 11
LUBRICATION POI NTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
MATCH
UP M ARKS
FRONT BACK
Figure 9
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 7 of 9
Revision: A Revision Date: 01-10-08
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
Miscrimps or Jams
Should this tool ever become stuck or
jammed i n a partially closed positi on, Do
Not f orce t he handles open or closed.
The tool will open easily by pressing up on
the rat chet rel ease lever in the movable
handle. S ee Fi gure 11
How to Adjust Tool Preload
(See Fi gure 10)
This hand tool i s f act ory preset t o 25-45
LBS . prel oad. It m ay be necessary over
the li f e of the t ool to adjust t ool handle
preload force. Li st ed bel ow are t he st eps
required to adj ust t he crim pi ng f orce of the hand tool t o obt ai n proper crimp condi t i ons:
1. Hold t he hand t ool i n t he pal m of your hand as shown i n Figure 12. Using the index f i nger squeeze the l ink
towards the top of t he hand t ool frame. This will release t he preload adjustm ent wheel.
2. Rotate t he setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force, rot ate the setting wheel clockwise (CW).
3. Release the l i nk to l ock the set ting wheel in pl ace.
4. Check the crimp specifi cat i ons or conduct a pull t est after t ool handl e prel oad force is adjusted.
Warranty
This tool i s f or el ectri cal t erm i nal crimpi ng purposes only. Thi s t ool i s made of the best qualit y m at eri al s. A l l vi t al
components are long l ife tested. All t ool s are warrant ed t o be free of manufacturing def ects f or a peri od of 30
days. Should such a defect occur, we will repair or exchange the tool f ree of charge. This repair or exchange will
not be appli cable t o al tered, mi sused, or dam aged t ool s. Thi s tool i s designed f or hand use only. Any clamping,
fixt uri ng, or use of handle extensions voids th is warrant y.
CAUTION: Mol ex crimp specif i cat i ons are valid onl y when used wit h M ol ex t erm inal s and t ool i ng.
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 8 of 9
Revision: A Revision Date: 01-10-08
CAUTIONS:
1. Manuall y powered hand t ool s are intended for low volum e or field repair. This tool i s NOT intended for
production use. Repetiti ve use of t hi s t ool should be avoided.
2. Insulated rubber handles are not prot ecti on agai nst el ect rical shock.
3. Wear eye protecti on at al l times.
4. Use only the M ol ex t erm i nals specif i ed f or crim pi ng wi th this t ool .
Certification
Molex does not cert i fy or re-certif y hand tool s but rather supplies the following gui del i nes f or custom ers t o re-cert i fy
hand tools.
%
This tool i s quali fied to pul l f orce onl y. To re-cert i fy, crimp a t erm i nal t o a wi re, which has been stripped
12.7mm (1/2”) long, so t here i s no crimpi ng of the insulat ion. Pull the termi nal and wire at a rate no f ast er than
25mm (1.00”) per minute. See the Mol ex web sit e f or the Qualit y Crim p Handbook f or m ore i nformati on on pul l
testing.
%
If t he tool does not meet minim um pull force values, handle preload should be increased and the pull test
rerun, (S ee How to Adju st P rel oad).
%
When the hand t ool is no l onger capable of achieving m i ni m um pul l force, it should be t aken out of service and
replaced.
Hand Crimp Tool f or 093” and Cl aspcon Pi n and S ocket and Com m oning Cri m p Term i nal s
Doc No: AT S -638191200 Releas e Dat e: 01-10-08 UNCO N TRO LLED CO PY Page 9 of 9
Revision: A Revision Date: 01-10-08
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PAR TS LIST
Item Number Order Number Description Quantity
REF 63819-1200 Hand Crim p Tool Figure 13
1 63819-1175 Locator Assembl y (Red) 1
1 63819-1176 Locator Assembly (Yellow) 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
Americas Headquar ters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
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Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Far East Sout h H ea dquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
Euro pean H eadquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Co rpo rate Hea dquart ers
2222 Wellington Ct.
Lis l e, IL 60532 U. S.A.
630-969-4550
Fax : 630-969-1352
Vi sit our Web si te at h ttp ://www.mol ex.com
