Hand Crimp Tool for 0.093, Claspcon Pin & Socket, and Commoning Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63828-0100
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 (see Page 2 and Page 3)
This tool is RoHS compliant; however RoHS, compliance is not required
SCOPE
Products:
Standard .093" Pin & Socket Crimp Terminals, Claspcon Pin & Socket Crimp Terminals, and
Commoning Terminals, 18 AWG stranded wire.
Terminal
Series
No.
1457-1
Insulation Diameter
Strip Length
IPC/WHMA-A-620 (1)
Terminal (2)
Loose Piece
Reel (3)
AWG mm²
mm
In.
mm
In.
mm
In.
05-02-0048 05-02-0047
1.58-2.60 .062-.102
02-08-1102 02-08-1101
1881-2
18
N/A 1.50 – 2.85 .059-.112 1.50-3.50 .059-.138 4.0-5.0
.16-.20
02-08-5101
1973
02-09-8104 02-09-8103
1.52-3.05 .060-.120
Insulation Diameter Notes
(1) Insulation diameter range for optimum (IPC/WHMA-A-620 Class 2) insulation crimps. Use tool profile specified on Page 3.
(2) Insulation diameter range for the terminal product design.
◊Terminal
Order No. Note
(3) Reeled terminals must be properly cut from the reel. See Terminal Cutoff Specifications on Page 2.
◊Terminal
Order No.
Wire Size
BEND UP
CONDUCTOR
CRIMP
INSULATION CRIMP
▲SEE
NOTE
DEFINITION OF TERMS
BRUSH
BELL MOUTH
ROLLING
TWISTING
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
Doc No: ATS-638280100
Revision: A
Release Date: 09-21-17
Revision Date: 09-21-17
UNCONTROLLED COPY
Page 1 of 8
Hand Crimp Tool for 0.093, Claspcon Pin & Socket, and Commoning Crimp Terminals
▲Insulation
Crimp Note
Due to the terminal’s insulation grip design or
insulation diameter range, this tool uses the overlap
form geometry in the insulation punch. This produces
an overlap insulation crimp (A-620-compliant).
Although 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.
OVERLAP FORM GEOMETRY
PUNCH
OVERLAP
INSULATION
CRIMP
ANVIL
WIRE
Terminal Cutoff Specifications
This hand tool operates best with loose-piece terminals. If reeled terminals are used, they must be cut from the
carrier strip as specified below.
Terminal Series Reeled Terminal
No.
Order No.
1457-1
1881-2
1973
05-02-0047
02-08-1101
02-08-5101
02-09-8103
Cutoff Dimension “X”
mm
0.18 maximum
3.61±0.08
In.
0.007 maximum
0.142±0.003
1457-1 SERIES
1881-2 SERIES
1973 SERIES
Doc No: ATS-638280100
Revision: A
Release Date: 09-21-17
Revision Date: 09-21-17
UNCONTROLLED COPY
Page 2 of 8
Hand Crimp Tool for 0.093, Claspcon Pin & Socket, and Commoning Crimp Terminals
After crimping, the crimped terminal should measure as follows:
Terminal Series
No.
1457-1
1881-2
1973
Terminal Locator
Wire Size
Conductor
Pull Force Minimum
Crimp Height
Crimp Width (Ref)
mm
In.
mm
In.
N
Lb.
1.37-1.43
.053-.056
2.00
.079
89
20
Order No. Color AWG mm
2
63828-0175 Blue
63828-0176 Yellow 18
N/A
63828-0177 Red
To achieve IPC/WHMA-A-620 Class 2 insulation crimps, use the appropriate tool profile for the insulation diameter:
Terminal Series
No.
1457-1
1881-2
1973
Wire Size
AWG mm
2
18
N/A
UL Style Insulation Diameter Range
(Ref)
mm
In.
1061
1.50-1.80
.059-.071
1007
1.70-2.00
.067-.079
1015
2.50-2.85
.098-.112
Insulation Crimp (Ref)
Tool Profile
Crimp Height Crimp Width
mm
In.
mm
In.
A B C
2.50 .098 2.20 .087
X
2.55 .100 2.20 .087
X
3.10 .122 2.99 .118
X
Crimp attribute specifications:
Terminal Series
No.
1457-1
1881-2
1973
Wire Size
AWG mm
2
18
N/A
Bell Mouth
mm
In.
0.2 – 0.5
0.008 – 0.02
Brush
mm
0.5 – 1.0
In.
0.02 – 0.04
Bend
Up
3°
Bend
Down
3°
Twist
Roll
4°
8°
Tool Qualification Notes
1. (Ref) means that the dimension provided is approximate because of the wide range of wires, conductor
stranding, insulation diameter and insulation hardness.
2. An occasional pull force test should be performed. It must exceed the minimum pull force specification.
3. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip the wire long
enough so the terminal insulation grips do not contact the wire insulation.
Doc No: ATS-638280100
Revision: A
Release Date: 09-21-17
Revision Date: 09-21-17
UNCONTROLLED COPY
Page 3 of 8
Hand Crimp Tool for 0.093, Claspcon Pin & Socket, and Commoning Crimp Terminals
OPERATION
CAUTION:
Crimp only the Molex terminals listed in the scope for this tool.
Do not crimp hardened objects as damage can occur to the tool frame or
crimp dies.
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.
HANDLE WILL
SPRING OPEN
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
SQUEEZE HANDLES
TOGETHER
Figure 1
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.
LOCATOR
IN DOWN
POSTION
PUSH ON
THE
LOCATOR
BUTTON
3. While holding the locator button in, load the terminal into the proper nest opening
in the locator based on the wire insulation diameter markings on the crimp jaws.
See Figure 3.
LOCATOR
PUSHED THROUGH
TOOLING
LOCATOR
BUTTON
PUSHED IN
LOCATOR
Figure 2
RELEASE
LOCATOR BUTTON
Figure 3
TERMINAL
TERMINAL
4.
5.
6.
7.
Release the locator button, allowing the locator to return to the crimping position.
Close the tool handle until the first ratchet position engages. See Figure 4.
Insert the properly stripped wire through the terminal and against the wire stop. See Figure 5.
Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws.
WIRE AGAINST
THE
WIRE STOP
WIRE STOP IS PART
OF THE LOCATOR
TERMINAL
WIRE
PRE-STRIPPED
WIRE
TERMINAL
Figure 5
Doc No: ATS-638280100
Revision: A
Release Date: 09-21-17
Revision Date: 09-21-17
UNCONTROLLED COPY
Page 4 of 8
Hand Crimp Tool for 0.093, Claspcon Pin & Socket, and Commoning Crimp Terminals
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.
WIRE
WIRE
STOP
TERMINAL
Locator Replacement
Figure 6
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. 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.
LOCATOR
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
TOP SLOTS OF
HANDTOOL
TOP HOOKS
Figure 8
PUSH ON
HANDLE
JAWS OPEN
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
PULL OPEN
TOOLING
M3 BHCS
TOOLING
Figure 7B
LOWER TABS
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’s 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.
Doc No: ATS-638280100
Revision: A
Release Date: 09-21-17
Revision Date: 09-21-17
UNCONTROLLED COPY
Page 5 of 8
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