Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63819-0500
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 IPC/WHMA A-620 Class 2 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.00mm (.079") Pitch Crimp Terminal, 24-30 AWG.
Terminal Series No.
50212
59354
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
50212-8100 39-00-0424 50212-8000 24-30 0.20-0.05 0.80-1.40 .031-055 1.30-1.80 .051-.071
59354-8181
59354-8081
24-30 0.20-0.05 0.80-1.40 .031-055 1.30-1.80 .051-.071
59354-8099
Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.
DEFINITION OF TERMS
SEAM
BRUSH
STRIP
LENGTH
BELL MOUTH
BEND UP
WIRE
TWISTING
INSULATION
CRIMP HEIGHT
ROLLING
CONDUCTOR
CRIMP HEIGHT
CUT OFF
TAB
BEND DOWN
Doc No: ATS-638190500
Revision: D
Release Date: 11-26-07
Revision Date: 01-26-12
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No
Wire Size
AWG
24
26
28
30
24
26
28
30
mm
2
0.20
0.12
0.08
0.05
0.20
0.12
0.08
0.05
Conductor Crimp
Height (Ref.)
Width (Ref.)
mm
In.
mm
In.
0.51-0.61 .020-.024 1.02 .040
0.51-0.61 .020-.024 1.02 .040
0.51-0.61 .020-.024 1.02 .040
0.51-0.61 .020-.024 1.02 .040
0.51-0.61 .020-.024 1.02 .040
0.51-0.61 .020-.024 1.02 .040
0.51-0.61 .020-.024 1.02 .040
0.51-0.61 .020-.024 1.02 .040
Insulation Crimp
Height (Ref.) Width (Ref.)
mm
In.
mm
In.
1.43 .056 1.40 .055
1.43 .056 1.40 .055
1.31 .052 1.29 .051
1.31 .052 1.29 .051
1.43 .056 1.40 .055
1.43 .056 1.40 .055
1.31 .052 1.29 .051
1.31 .052 1.29 .051
Pull Force
Minimum
N
Lb.
29.4
6.60
19.6
4.40
9.8
2.20
4.9
1.10
29.4
6.60
19.6
4.40
9.8
2.20
4.9
1.10
Profile
24-26
X
X
28-30
50212
X
X
X
X
X
X
59354
•
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 FORM GEOMETRY
PUNCH
▲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
ANVIL
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).
OVERLAP
INSULATION
CRIMP
WIRE
CAUTION:
Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
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 performed
to check hand tool crimp. Pull Force value Must
exceed the Minimum pull force specifications
listed.
HANDLE WILL
SPRING OPEN
LOCATOR
IN DOWN
POSTION
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. See Figure 1.
Doc No: ATS-638190500
Revision: D
Release Date: 11-26-07
Revision Date: 01-26-12
SQUEEZE
HANDLES
TOGETHER
Figure 1
Figure 2
PUSH ON THE
LOCATOR BUTTON
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
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 the locator button in, 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.
LOCATOR
PUSHED THRU
TOOLING
LOCATOR
RELEASE
LOCATOR BUTTON
LOCATOR
BUTTON
PUSHED IN
TERMINAL
TERMINAL
Figure 3
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
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.
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 4
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE STOP IS
PART OF
THE LOCATOR
PRE-STRIPPED
WIRE
Figure 5
WIRE
TERMINAL
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Doc No: ATS-638190500
Revision: D
Release Date: 11-26-07
Revision Date: 01-26-12
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
WIRE
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.
WIRE STOP
Figure 6
TERMINAL
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.
LOCATOR
1. Open the crimp hand tool.
SQUEEZE
2. Squeeze gently on the lower area shown in
HERE
Figure 7A with your thumb and index finger.
The lower tabs of the locator should
SQUEEZE
disengage from the hand tool.
HERE
3. Lift and pull away from the hand tool. The
Figure 7A
TOP SLOTS OF
top locator hooks should slip out of the top
HANDTOOL
slots easily. See Figure 7A.
4. To reinstall the new locator, make sure the
TOP HOOKS
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
locators top hooks (2) into the hand tool top
slots.
7. Rotate the locator down and press the lower
LOWER TABS
tabs into the two bottom slots of the hand
tool. To secure the locator into place, the lower
JAWS OPEN
tabs must snap into place on the hand tool frame.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
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 if using the left handed application along with the
locator. Follow the steps below:
PULL OPEN
TOOLING
M3 BHCS
TOOLING
Figure 8
PUSH ON
HANDLE
Doc No: ATS-638190500
Revision: D
Release Date: 11-26-07
Revision Date: 01-26-12
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
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.
MATCH
UP MARKS
Figure 9
FRONT
BACK
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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
4. Wipe excess oil from hand tool, particularly from crimping area. Oil
Figure 10
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 up on the ratchet release lever in the movable handle. See Figure
11.
RATCHET RELEASE
LEVER
How to Adjust Tool Preload
(See Figure 12)
Figure 11
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:
Doc No: ATS-638190500
Revision: D
Release Date: 11-26-07
Revision Date: 01-26-12
UNCONTROLLED COPY
Page 5 of 7
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