Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire)
Doc No: ATS-6382521HM Release Date: 01-31-12
UNCONTROLLED COPY
Page 1 of 6
Revision: A Revision Date: 01-31-12
CONDUCTOR
BRUSH
SEAM
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND DOWN
WIRE
INSULATION CRIMP
▲SEE NOTE
INSULATION
SLEEVE
Application Tooling
Specification Sheet
Modular Crimp Head
Order No.
6382
5
2
1
70
Hand Crimp Tool
Order No.
6
382
5
2
1
00
FEATURES
% A full cycle ratcheting hand tool ensures complete crimps
% Ergonomically designed soft handles
% Precisely designed crimping profiles with simple contact positioning
% Easy handling due to outstanding force ratio
% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
% Can also be used in the Battery Powered Tool Order No. 63816-0200 (110 V) or 63816-0250 (220 V)
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: .110 Receptacle Terminals, 19 and 20.5 AWG Magnet Wires.
Terminal
Series No.
Terminal
Order No.
Magnet Wire Size and Type
AWG
Bare Wire Insulated
Diameter (mm Approximately)
CMA
Diameter (mm Approximately)
CMA
49748 49748-9001
19.0 .912 1289
.970 1459
20.5
.767 912 .823 1050
Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4A
Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire)
Doc No: ATS-6382521HM Release Date: 01-31-12 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 01-31-12
INSULATION
SLEEVE LOCATION
10.0 Minimum
Reference
INSULATION SLEEVE
5.4 to 7.3
▲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).
CRIMP SPECIFICATIONS:
Terminal Series No. Bell mouth Conductor Brush Max.
mm In. mm In.
49748 0.30-0.80 .012-.031 0.50-1.80 .020-.071
Terminal Series No. Bend up Bend down Twist Roll Seam
Seam shall not be open and no wire
allowed out of the crimping area
Degree Degree
49748 5 5 3 5
After crimping, the conductor profile should measure the following.
Terminal Series No. Wire Size Conductor Crimp Pull Force Minimum Profile
Height Width
AWG mm In. mm In. N Lb. 19 AWG
20.5 AWG
49748 19.0 1.13-1.17 .044-.046 1.82-1.88 .072-.074 103.0 23.2 X
20.5 1.06-1.10 .042-.043 1.82-1.88 .072-.074 94.1 21.2 X
Terminal
Series No.
Wire Size Insulation Crimp Insulation Sleeve
Height Width Material Diameter (Ref) Length (Ref)
AWG mm In. mm In. mm In. mm In.
49748 19.0 2.00-2.10 .079-.083 2.60-2.70 .102-.106 Teflon Tubing
TFS-19 ~ 21
0.97 .038 10.0 Min .394 Min.
20.5 2.00-2.10 .079-.083 2.60-2.70 .102-.106 0.86 .034
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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
SLEEVE
AND WIRE
Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire)
Doc No: ATS-6382521HM Release Date: 01-31-12 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 01-31-12
WIRE
INSULATION
PUNCH
TERMINAL
WIRE STOP BLADE
Figure 1
Figure 2
SLEEV
AND
WIRE
TERMINAL
LOCATOR
INSULATION
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR
ANVIL
CONDUCTOR
PUNCH
OPERATION
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. Place the terminal into the correct die profile until the terminal stopped by the locator.
2. Bring the wire stop blade down; make sure the wire stop located behind the conductor grip.
3. Place a pre-striped wire into the terminal until the end of wire touching the wire stop. See Figure 2.
4. Close the tool until the ratchet releases, the tool handles will then spring open.
5. Carefully remove the crimped terminal.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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.
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.
Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire)
Doc No: ATS-6382521HM Release Date: 01-31-12 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 01-31-12
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 lifting the ratchet release lever. See Figure 6.
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: Repetitive use of this tool should be avoided.
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.
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all
insulation sizes.
4. Molex does not repair hand tools (see warranty above) The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips
on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
6. Molex does not certify crimp hand tools.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
Applications for the Modular Crimp Head
WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper Manual or Specification Sheet.
See Chart below for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging or turn off the Actuator from its power source.
CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.
Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire)
Doc No: ATS-6382521HM Release Date: 01-31-12 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 01-31-12
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR POWER
CRIMP
ADAPTER
CAUTION: Wear safety glasses when operating or serving this tool.
The chart below shows all applications for this Modular Crimp Head.
Modular Crimp Head
Order No.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63825-2170
63816-0000
Hand Crimp Frame (Short) N/A N/A 3
63816-0050
Hand Crimp Frame (Long) N/A N/A 3
63816-0200
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
4
63816-0250
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
4
63816-0100
Air Power Tool 63816-0700
Air Power Crimp Adapter 5
Applications for the Modular Crimp Head
Hand Crimp Tool Battery Powered Tool Air Powered Tool
Figure 3 Figure 4 Figure 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT
Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire)
Doc No: ATS-6382521HM Release Date: 01-31-12 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 01-31-12
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
2
5
1
M4 X 14mm
LONG BHCS
PARTS LIST
Hand Crimp Tool 63823-2500
Item
Order Number
Description Quantity
1 63825-2170 Modular Crimp Head 1 (Ref)
2 63816-0050 Hand Crimp Frame (Long)
1 (Ref)
3 63825-2175 Locator 1
4
63816
-
0001
Locking
Pin
2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
http://www.molex.com