Hand Crimp Tool for MLX™ Pin and Socket Crimp Terminals
Doc No: ATS-638116800 Release Date: 09-18-06 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 03-28-08
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
TYPE 2C
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811-6800
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
This tool is WHMA-IPCA620 Class 2 and RoHS compliant
SCOPE
Products: MLX™ Pin and Socket Crimp Terminal 14 - 20 AWG.
Terminal Order No. Wire Size
Insulation
Diameter Maximum Strip Length Terminal
Series No.
Loose Piece
Reel AWG mm² mm In. mm In.
02-08-2004
02-08-2010
02-08-2003
02-08-2009
02-08-2006
02-08-2012
02-08-2005
02-08-2011
42023
02-08-2008
02-08-2007
14-20
2.00-0.50
1.52-3.30
.060-.130
3.96-5.53
.156-.218
02-08-1002
02-08-1006
02-08-1001
02-08-1005
42024 02-08-1004
02-08-1008
02-08-1003
02-08-1007
14-20
2.00-0.50
1.52-3.30
.060-.130
3.96-5.53
.156-.218
Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.
See Conditions on page 2
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Hand Crimp Tool for MLX™ Pin and Socket Crimp Terminals
Doc No: ATS-638116800 Release Date: 09-18-06 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 03-28-08
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 5).
Conductor Crimp Insulation Crimp
Wire Size Height (Ref.) Width (Ref.)
Height (Ref.)
Width (Ref.)
Pull Force
Minimum
Profile
Terminal
Series No.
AWG
mm
2 mm In. mm In. mm In. mm In. N Lb. A
B
C
14 2.00 1.55-1.65
.061-.065
2.71 .107 3.24 .127 3.13 .123 222.4
50.00
X
16 1.30 1.40-1.50
.055-.059
2.50 .098 2.88 .113 3.10 .122 133.4
30.00
X
18 0.80 1.30-1.40
.051-.055
2.24 .088 2.40 .094 2.83 .111 88.9 20.00
X
42023
20 0.50 1.30-1.40
.051-.055
2.23 .088 2.38 .093 2.79 .110 57.8 13.00
X
14 2.00 1.55-1.65
.061-.065
2.71 .107 3.24 .127 3.13 .123 222.4
50.00
X
16 1.30 1.40-1.50
.055-.059
2.50 .098 2.88 .113 3.10 .122 133.4
30.00
X
18 0.80 1.30-1.40
.051-.055
2.24 .088 2.40 .094 2.83 .111 88.9 20.00
X
42024
20 0.50 1.30-1.40
.051-.055
2.23 .088 2.38 .093 2.79 .110 57.8 13.00
X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile A: 2.30-3.30mm (.090-.130 inch)
Profile B: 1.90-2.90mm (.075-.114 inch)
Profile C: 1.52-2.70mm (.060-.106 inch)
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.
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
2. Swing the terminal locator away from the crimp tool shown in Figure 2.
Some terminals with large insulation grips may interfere with the crimp
tooling when swinging the locator into position. The terminal must then be
loaded into the locator in the closed/crimp position.
3. When using the locator, press down on the wire stop on the locator as
shown in Figure 2. Insert the proper terminal into the proper nest opening.
Make sure when choosing the nest opening, it will correspond with the A,
B, or C profile on the hand tool.
4. Return the locator to its original position. Insert the proper wire over the
terminal. Some large O.D. wires may need to be placed into the terminal before closing the tool. Gently touch
the wire stop with the end of the wire. See Figure 3.
5. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Figure 1
LOCATOR
JAWS OPEN
Hand Crimp Tool for MLX™ Pin and Socket Crimp Terminals
Doc No: ATS-638116800 Release Date: 09-18-06 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 03-28-08
6. Remove the crimped terminal from the terminal locator by pressing
down on the wire stop and gently pulling on the wire. The terminal
locator can be in either position.
7. Visually inspect the crimped terminal for proper crimp location.
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, 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 on page 2.
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.
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the
hand tool.
3. Firmly press down on the brass pivot shaft with your
thumb, while pulling the locator up. Slip the locator off
the top of the brass pivot shaft. See Figure 4.
4. Replace it with the desired locator by putting over the
brass pivot shaft and snapping it into place.
TERMINAL
PUSH HERE
TOOPEN WIRE
STOP
SWING OPEN
LOCATOR
LOCATOR
TERMINAL
IN PLACE
Figure 2
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE AGAINST
STOP
Figure 3
WIRE STOP
WIRE
SWING
LOCATOR
OPEN
PRESS
DOWN
ON BRASS
PIVOT SHAFT
LIFT UP LOCATOR
JAWS OPEN
Figure 4
Hand Crimp Tool for MLX™ Pin and Socket Crimp Terminals
Doc No: ATS-638116800 Release Date: 09-18-06 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 03-28-08
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 fine piece of equipment it needs cleaning and
lubrication for a maximum service life of trouble free crimping. Use light oil, such as 30 weight automotive oil, at
the oil points. Every 5,000 crimps, or 3 months, to significantly enhance the tool life. See Figure 6.
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
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 the ratchet release lever. See Figure
6.
How to Adjust Tool Preload
(See Figure 6)
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. Remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel.
2. Remove the locking screw with a 2mm hex wrench. The wrench set (63810-0101), is not supplied. It is sold
separately from the hand tool.
3. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase handle
force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.
RATCHET
RELEASE
LEVER
Figure 6
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 5
Hand Crimp Tool for MLX™ Pin and Socket Crimp Terminals
Doc No: ATS-638116800 Release Date: 09-18-06 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 03-28-08
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.
Certification
Molex does not certify or re-certify commercial grade 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 MLX™ Pin and Socket Crimp Terminals
Doc No: ATS-638116800 Release Date: 09-18-06 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 03-28-08
RATCHET
RELEASE
LEVER
2
Figure 7
M4 X 5LG
BHCS
3
4
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63811-6800 Hand Crimp Tool Figure 7
1 63810-0101 Wrench Set (Not included) 0
2 63810-0102 Locator Base Assembly 1
3 63810-0103 Repair Kit (Not included) 0
4 63811-6875 Locator 1
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
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