Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 1 of 9
Revision: B Revision Date: 08-07-12
HAND CRIMP
TOOL
Application Tooling
Specification Sheet Order No. 63819-1100
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 WHMA-IPCA620 Class 2 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.36mm (.093") Diameter, Standard .093" Pin and Socket Crimp Terminals, 14-20 AWG,
3.18mm (.125") Diameter, Standard .125" Pin and Socket Crimp Terminals, 16-18 AWG,
and Commoning Terminals, 14-16 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Loose Piece
•
Reel AWG
mm² mm In. mm In.
1189
02
-
09
-
1103
39
-
00
-
0288
14-20
2.08-0.52
1.65-4.06 .065-.160 3.30-3.80
.130-.150
02
-
09
-
1104
39
-
00
-
0289
02
-
09
-
5106
39
-
00
-
0294
02
-
09
-
5111
39
-
00
-
0295
39
-
00
-
0072
1190
02
-
09
-
2103
39
-
00
-
0297
14-20
2.08-0.52
1.65-4.06 .065-.160 3.30-3.80
.130-.150
02
-
09
-
6106
39
-
00
-
0299
02
-
09
-
6
110
1457
-
2
05
-
02
-
0050
05
-
02
-
0049
14
-
16
2.08
-
1.31
3.56 Max.
.140 Max.
3.30
-
3.80
.130
-
.150
1973
-
2
02
-
09
-
8109
14
-
18
2.08
-
0.82
4.06 Max.
.160 Max.
3.30
-
3.80
.130
-
.150
2046
18
-
12
-
2222
16
-
18
1.31
-
0.82
3.05 Max.
.120 Max.
3.30
-
3.80
.130
-
.150
2047
18
-
12
-
1222
16
-
18
1.31
-
0.82
3.05 Max.
.120 Max.
3.30
-
3.80
.130
-
.150
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
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: 0.18mm (.007”) maximum Cut-off Tab.
See Conditions on page 3.
TYPE 4D
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 2 of 9
Revision: B Revision Date: 08-07-12
INSULATION CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 – compliant). While
the insulation punch profile may appear
“lopsided”, this is a normal condition for this
tool. See figure to the right. (Some tools with
multiple crimp pockets may not have the
“overlap” profile on all pockets).
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal Series No
Wire Size
Conductor Crimp
Insulation Crimp
AWG
mm
2
Height (Ref.)
Width (Ref.)
Height (Ref.)
Width (Ref.)
1189
14
2.08
1.62
-
1.72
.064
-
.068
2.36
.093
3.25
.12
8
3.50
.138
16
1.31
1.46
–
1.56
.057
-
.061
2.36
.093
3.09
.122
3.43
.135
18
0.82
1.35
–
1.45
.053
-
.057
2.08
.082
2.74
.108
3.09
.122
20
0.52
1.30
–
1.40
.051
-
.055
2.08
.082
2.65
.104
3.02
.119
1190
14
2.08
1.62
-
1.72
.064
-
.068
2.36
.093
3.25
.128
3.
50
.138
16
1.31
1.46
–
1.56
.057
-
.061
2.36
.093
3.09
.122
3.43
.135
18
0.82
1.35
–
1.45
.053
-
.057
2.08
.082
2.74
.108
3.09
.122
20
0.52
1.30
–
1.40
.051
-
.055
2.08
.082
2.65
.104
3.02
.119
1457-2
14
2.08
1.62
-
1.72
.064
-
.068
2.40
.094
3.25
.128
3.53
.139
16
1.31
1.52
–
1.62
.060
-
.064
2.35
.093
3.16
.124
3.48
.137
1973-2
14
2.08
1.62
–
1.72
.064
-
.068
2.39
.094
3.23
.127
3.50
.138
16
1.31
1.52
–
1.62
.060
-
.064
2.35
.093
3.15
.124
3.44
.135
18
0.82
1.37
–
1.47
.054
-
.058
2.09
.082
2.76
.109
3.07
.
121
2046
16
1.31
1.6
5
–
1.7
5
.065
-
.069
2.38
.094
3.30
.130
3.55
.140
18
0.82
1.57
–
1.67
.062
-
.066
2.34
.092
3.19
.126
3.47
.137
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 3 of 9
Revision: B Revision Date: 08-07-12
Terminal Series No
Wire Size
Conductor Crimp
Insulation Crimp
AWG
mm
2
Height (Ref.)
Width (Ref.)
Height (Ref.)
Width (Ref.)
2047
16
1.31
1.6
5
–
1.7
5
.065
-
.069
2.38
.094
3.30
.130
3.55
.140
18
0.82
1.57
–
1.67
.062
-
.066
2.34
.092
3.19
.126
3.47
.
137
4549
14
2.08
1.57
-
1.67
.062
-
.066
2.39
.094
3.20
.126
3.49
.137
16
1.31
1.46
–
1.56
.057
-
.061
2.35
.093
3.10
.122
3.46
.136
18
0.82
1.33
–
1.43
.052
-
.056
2.08
.082
2.72
.107
3.08
.121
20
0.52
1.25
–
1.35
.049
-
.053
2.07
.081
2.65
.104
3.00
.118
4550
14
2.08
1.57
-
1.67
.062
-
.066
2.39
.094
3.20
.126
3.49
.137
16
1.31
1.46
–
1.56
.057
-
.061
2.35
.093
3.10
.122
3.46
.136
18
0.82
1.33
–
1.43
.052
-
.056
2.08
.082
2.72
.107
3.08
.121
20
0.52
1.25
–
1.35
.049
-
.053
2.07
.081
2.65
.104
3.00
.118
7238
14
2.08
1.69
–
1.79
.067
-
.070
2.40
.094
3.24
.128
3.51
.138
16
1.31
1.6
5
–
1.7
5
.065
-
.069
2.38
.094
3.24
.128
3.51
.138
18
0.82
1.59
–
1.69
.063
-
.067
2.37
.093
3.18
.125
3.46
.136
Terminal Series No
Wire Size
P
ull
Force
Min
imum
Profile
Locator
AWG
mm
2
N
Lb.
A
B
Order No.
Color
1189
14
2.08
178.0
40.00
X
63819-1175 Red
16
1.31
155.0
35.00
X
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
1190
14
2.08
178.0
40.00
X
63819-1175 Red
16
1.31
155.0
35.00
X
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
1457-2
14
2.08
178.0
40.00
X
63819-1176 Yellow
16
1.31
155.0
35.00
X
1973-2
14
2.08
178.0
40.00
X
63819-1176 Yellow
16
1.31
155.0
35.00
X
18
0.82
111.3
25.00
X
2046
16
1.31
155.0
35.00
X
63819-1177 Gray
18
0.82
111.3
25.00
X
2047
16
1.31
155.0
35.00
X
63819-1177 Gray
18
0.82
111.3
25.00
X
4549
14
2.08
178.0
40.00
X
63819-1175 Red
16
1.31
155.0
35.00
X
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
4550
14
2.08
178.0
40.00
X
63819-1175 Red
16
1.31
155.0
35.00
X
18
0.82
111.3
25.00
X
20
0.52
66.8
15.00
X
7238
14
2.08
178.0
40.00
X
63819-1175 Red
16
1.31
155.0
35.00
X
18
0.82
111.3
25.00
X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges
are recommended:
1. Profile A: 3.00mm - 2.20mm (.118 - 087 inch)
2. Profile B: 2.85mm -2.00mm (.112 - .079 inch)
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 4 of 9
Revision: B Revision Date: 08-07-12
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
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 preformed to check hand tool crimp. Pull Force value Must exceed
the Minimum pull force specifications listed.
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.
Crimping Terminals
1. Select the desired terminal listed from the preceding charts and install the proper locator (See chart above and
see Locator Installation 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.
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.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 5 of 9
Revision: B Revision Date: 08-07-12
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF THE
LOCATOR
PRE
-
STRIPPED
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.
Locator Installation
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.
TERMINAL
Figure 6
WIRE
WIRE STOP
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
SQUEEZE
HERE
LOCATOR
Figure 7A
SQUEEZE
HERE
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 6 of 9
Revision: B Revision Date: 08-07-12
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 locator 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.
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 along with the locator if using the left handed application. Follow
the steps below:
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 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.
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. 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.
RATCHET RELEASE
LEVER
Figure 11
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
MATCH
UP MARKS
FRONT
BACK
Figure 9
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 7 of 9
Revision: B Revision Date: 08-07-12
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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
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 11
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:
1. Hold the hand tool in the palm of your hand as shown in Figure 12. 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.
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.
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.
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 8 of 9
Revision: B Revision Date: 08-07-12
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.
Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals
Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 9 of 9
Revision: B Revision Date: 08-07-12
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63819
-
1100
Hand Crimp Tool
Figure 13
1
63819
-
1175
Locator Assembly (Red)
1
1
63819
-
1176
Locator Assembly (Yellow)
1
1
63819
-
1177
Locator Assembly (
Gray
)
1
2
63810
-
0104
Spring, Return
1
3
63810
-
0105
Spring, Ratchet
1
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