Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals HAND CRIMP TOOL Application Tooling TYPE 4D Specification Sheet Order No. 63819-1100 FEATURES (cid:1) A full cycle ratcheting hand tool ensures complete crimps (cid:1) Ergonomic soft grip handles for comfortable crimping (cid:1) A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position (cid:1) Right and Left handed applications (cid:1) This tool is WHMA-IPCA620 Class 2 compliant as indicated (cid:1) 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 Terminal Order No. Wire Size (cid:1) Insulation Diameter Strip Length Series No. Loose Piece • Reel AWG mm² mm In. mm In. 02-09-1103 39-00-0288 02-09-1104 39-00-0289 1189 02-09-5106 39-00-0294 14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150 02-09-5111 39-00-0295 39-00-0072 02-09-2103 39-00-0297 1190 02-09-6106 39-00-0299 14-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.150 02-09-6110 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. (cid:1) See Conditions on page 3. 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 For .093” and .125” Pin and Socket and Commoning Crimp Terminals DEFINITION OF TERMS BEND UP BRUSH BELL MOUTH CONDUCTOR CRIMP INSULATION CRIMP ROLLING ▲SEE NOTE TWISTING STRIP LENGTH BEND DOWN CRIMP HEIGHT The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. 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 OVERLAP the insulation punch profile may appear INSULATION “lopsided”, this is a normal condition for this CRIMP tool. See figure to the right. (Some tools with multiple crimp pockets may not have the “overlap” profile on all pockets). WIRE CONDITIONS: ANVIL After crimping, the conductor profiles should measure the following. Wire Size Conductor Crimp Insulation Crimp Terminal Series No AWG mm2 Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) 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 1189 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 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 1190 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 14 2.08 1.62 - 1.72 .064-.068 2.40 .094 3.25 .128 3.53 .139 1457-2 16 1.31 1.52 – 1.62 .060-.064 2.35 .093 3.16 .124 3.48 .137 14 2.08 1.62 – 1.72 .064-.068 2.39 .094 3.23 .127 3.50 .138 1973-2 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 16 1.31 1.65 – 1.75 .065-.069 2.38 .094 3.30 .130 3.55 .140 2046 18 0.82 1.57 – 1.67 .062-.066 2.34 .092 3.19 .126 3.47 .137 Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 2 of 9 Revision: B Revision Date: 08-07-12

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals Wire Size Conductor Crimp Insulation Crimp Terminal Series No AWG mm2 Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) 16 1.31 1.65 – 1.75 .065-.069 2.38 .094 3.30 .130 3.55 .140 2047 18 0.82 1.57 – 1.67 .062-.066 2.34 .092 3.19 .126 3.47 .137 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 4549 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 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 4550 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 14 2.08 1.69 – 1.79 .067-.070 2.40 .094 3.24 .128 3.51 .138 7238 16 1.31 1.65 – 1.75 .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 Wire Size Pull Force Minimum (cid:1) Profile Locator Terminal Series No AWG mm2 N Lb. A B Order No. Color 14 2.08 178.0 40.00 X 16 1.31 155.0 35.00 X 1189 63819-1175 Red 18 0.82 111.3 25.00 X 20 0.52 66.8 15.00 X 14 2.08 178.0 40.00 X 16 1.31 155.0 35.00 X 1190 63819-1175 Red 18 0.82 111.3 25.00 X 20 0.52 66.8 15.00 X 14 2.08 178.0 40.00 X 1457-2 63819-1176 Yellow 16 1.31 155.0 35.00 X 14 2.08 178.0 40.00 X 1973-2 16 1.31 155.0 35.00 X 63819-1176 Yellow 18 0.82 111.3 25.00 X 16 1.31 155.0 35.00 X 2046 63819-1177 Gray 18 0.82 111.3 25.00 X 16 1.31 155.0 35.00 X 2047 63819-1177 Gray 18 0.82 111.3 25.00 X 14 2.08 178.0 40.00 X 16 1.31 155.0 35.00 X 4549 63819-1175 Red 18 0.82 111.3 25.00 X 20 0.52 66.8 15.00 X 14 2.08 178.0 40.00 X 16 1.31 155.0 35.00 X 4550 63819-1175 Red 18 0.82 111.3 25.00 X 20 0.52 66.8 15.00 X 14 2.08 178.0 40.00 X 7238 16 1.31 155.0 35.00 X 63819-1175 Red 18 0.82 111.3 25.00 X (cid:1) 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. Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 3 of 9 Revision: B Revision Date: 08-07-12

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals Note: A crimp height chart is provided with this manual as Reference Only. Due to the HANDLE WILL wide range of wires, strands, insulation diameters, and durometers available, actual SPRING OPEN 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. SQUEEZE HANDLES Open the tool by squeezing the handles together. At the end of the closing stroke, TOGETHER the ratchet mechanism will release the handles and the hand tool will spring open. See Figure 1. 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. LOCATOR IN RELEASE DOWN POSTION LOCATOR BUTTON TERMINAL LOCATOR PUSHED THRU TOOLING LOCATOR BUTTON PUSHED IN PUSH ON THE Figure 3 Figure 2 LOCATOR BUTTON TERMINAL TOOLING PARTIALLY CLOSED 3. While holding in the locator button, load the terminal into the proper PARTIALLY nest opening in the locator, based on the wire gauge or terminal type CLOSE HANDLE 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 OPEN POSITION 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 FIRST RATCHET mechanism cycle has been completed. Release the handles to open POSITION the jaws. Figure 4 Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 4 of 9 Revision: B Revision Date: 08-07-12

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals WIRE STOP IS PART OF THE LOCATOR WIRE AGAINST TERMINAL THE WIRE STOP PRE-STRIPPED WIRE Figure 5 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 WIRE 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 WIRE STOP open position. Insert the wire above the terminal in the punch and against the wire stop then close the tool. See Figure 6. Figure 6 Locator Installation TERMINAL 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 SQUEEZE HERE JAWS OPEN MAKE SURE SQ UEEZE CENTER OF LOCATOR PULL OPEN HERE IS IN THE TOOLING DOWN POSITION TOOLING TOP SLOTS OF M3 BHCS HANDTOOL TOP HOOKS Figure 8 Figure 7B PUSH ON HANDLE Figure 7A LOWER TABS Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 5 of 9 Revision: B Revision Date: 08-07-12

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals 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 MATCH (2) into the hand tool top slots. UP MARKS 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. Figure 9 Right or Left Hand Operation FRONT BACK 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 LUBRICATION POINTS section. (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) Maintenance It is recommended that each operator of the tool be made aware of, and Figure 10 responsible for, the following maintenance steps: 1. Remove dust, moisture, and other contaminants with a clean brush, or soft, RATCHET RELEASE lint free cloth. LEVER 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 Figure 11 transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application. Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 6 of 9 Revision: B Revision Date: 08-07-12

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals 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. SQUEEZE Miscrimps or Jams THE LINK IN HOLD THE HAND RATCHET THE HANDLE TOOL IN POSITION RELEASE LEVER 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 Figure 12 LBS. preload. It may be necessary over SETTING the life of the tool to adjust tool handle WHEEL 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. Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 7 of 9 Revision: B Revision Date: 08-07-12

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals 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. Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 8 of 9 Revision: B Revision Date: 08-07-12

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals 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 2 1 RATCHET RELEASE LEVER Figure 13 3 Visit our Web site at http://www.molex.com Doc No: ATS-638191100 Release Date: 01-09-08 UNCONTROLLED COPY Page 9 of 9 Revision: B Revision Date: 08-07-12

Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: M olex: 63819-1175 63819-1176 63819-1177