Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals
Doc No: ATS-638194300 Release Date: 02-11-09 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 02-11-09
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
Specification Sheet
Order No. 63819-4300
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: 1.20mm (.047”) Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal, 28-30 AWG.
Insulation Diameter
Wire Size IPC/WHMA-A620 Terminal

Strip Length
Terminal
Series No.
Terminal Order No.
Reel Form Only AWG
mm² mm In. mm In. mm In.
78172-0410
78172 78172-0411 28-30
0.08-0.05
0.50-0.70
.020-.028
0.50-0.70
.020-.028
0.90-1.30
.035-.051
To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
Overall insulation OD specification for terminal.
Customer to cut off terminal from reel: 0.05mm (.002”) maximum Cut-off Tab.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
TYPE 4D
Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals
Doc No: ATS-638194300 Release Date: 02-11-09 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 02-11-09
RELEASE
LOCATOR
BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATO
R
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Conductor Crimp (Ref) Insulation Crimp (Ref)
Wire Size Height Width Height Width
Pull Force
Minimum Profile
Terminal
Series No
AWG
mm2
mm In. Mm In. mm In. mm In. N Lb. AWG 30
AWG 28
28 0.08 0.44-0.48
.017-.019
0.85
.033
0.77
.030
0.85
.033
10.0
2.25
X
78172 30 0.05 0.40-0.44
.015-.017
0.85
.033
0.75
.029
0.85
.033
5.0 1.12
X
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. See Figure 1.
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
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals
Doc No: ATS-638194300 Release Date: 02-11-09 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 02-11-09
PRE
-
STRIPPED
WIRE
TERMINAL
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE
WIRE STOP IS
PART
OF THE LOCATOR
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.
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.
TERMINAL
Figure 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals
Doc No: ATS-638194300 Release Date: 02-11-09 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 02-11-09
Figure
8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
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.
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. 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 locators 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.
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:
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.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals
Doc No: ATS-638194300 Release Date: 02-11-09 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 02-11-09
MATCH
UP MARKS
FRONT
BACK
Figure 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 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.
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 up on the ratchet release lever in the movable handle. See Figure
11.
How to Adjust Tool Preload (See Figure 12)
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. Hold the hand tool in the palm of your hand as shown in Figure 10.
Using the index finger squeeze the link towards the top of the hand tool
frame. This will release the preload adjustment wheel.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11
Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals
Doc No: ATS-638194300 Release Date: 02-11-09 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 02-11-09
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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.
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.
Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals
Doc No: ATS-638194300 Release Date: 02-11-09 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 02-11-09
RATCHE
T
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63819-4300 Hand Crimp Tool Figure 13
1 63819-4375 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
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81-462-65-2324
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630-969-4550
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