Page 1
Hand Crimp Tool for 1.25mm (.049") Pitch Crimp Terminals
INSULATION
BRUSH
STRIP
BELL
CRIMP HEIGHT
BEND
BEND UP
ROLLING
CONDUCTOR
TWISTING
CUT-OFF
SEAM
HAND CRIMP TOOL
Operating Instruction and
Specification Sheet
Order No. 63811-0300
FEATURES
Ratchet with safety release that ensures consistent performance
Small handle spread which make this style tool ideally suited for end users
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
SCOPE
Products: 1.25mm (.049") Pitch PicoBlade™ Crimp Terminal, 28-32 AWG and 1.25mm (.049") Pitch Board-In
Crimp Terminal, 28-32 AWG.
Terminal Order No. Wire Size Insulation Diameter Strip Length Terminal
Series No.
50079
50080 50080-8100 50080-8000
50125 50125-8100 50125-8000
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
LENGTH
Loose Piece
50079-8100 50079-8000 39-00-0413
50079-8153 50079-5053 39-00-0414
Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.
Reel AWG mm² mm In. mm In.
26-28 0.12-0.08 0.67-1.00 .027-.039 1.40-1.91 .055-.075
26-28 0.12-0.08 0.67-1.00 .027-.039 1.40-1.91 .055-.075
MOUTH
CRIMP
TAB
26-28 0.12-0.08 0.67-1.00 .027-.039 1.40-1.91 .055-.075
CRIMP
DOWN
Doc No: ATS-638110300 Release Date: 12-10-03 UNCONTROLLED COPY Page 1 of 5
Revision: J Revision Date: 04-14-08
Page 2
Hand Crimp Tool for 1.25mm (.049") Pitch Crimp Terminals
INSULATION CRIMP FORM
This crimp terminal is designed for miniaturization; therefore, each dimension of insulation crimp portion appears
small as compared to the terminal material thickness. In order to avoid insulation piercing the crimp forms by the
insulation barrel, coining is provided inside of the insulation barrel. For this reason, various crimp forms will occur at
the tip of the insulation crimp barrel shown in the figure below.
These crimp forms maybe changed completely by a small change in the wire, insulation punch, or terminal.
These crimp forms are satisfactory for original function of the insulation crimp portion and it is confirmed that all of
these forms below are acceptable insulation crimps.
CONDITIONS
After crimping, the conductor profiles should measure the following (See notes on page 4).
Conductor Crimp
Terminal Series No.
50079
50080
50125
Wire Size
AWG
mm
2
26 0.12 0.60-0.65 .0236-.0256 0.83 .033 9.8 2.20 X
28 0.08 0.56-0.61 .022-.024 0.83 .033 9.8 2.20 X
26 0.12 0.58-0.64 .023-.025 0.83 .033 9.8 2.20 X
28 0.08 0.55-0.60 .0216-.0236 0.83 .033 9.8 2.20 X
26 0.12 0.58-0.64 .023-.025 0.83 .033 9.8 2.20 X
28 0.08 0.55-0.60 .0216-.0236 0.83 .033 9.8 2.20 X
Height (Ref) Punch Width (Ref)
mm In. mm In. N Lb. A B
Pull Force
Minimum
Profile
Doc No: ATS-638110300 Release Date: 12-10-03 UNCONTROLLED COPY Page 2 of 5
Revision: J Revision Date: 04-14-08
Page 3
Hand Crimp Tool for 1.25mm (.049") Pitch Crimp Terminals
TERMINAL
PRE-STRIPPED
WIRE
Figure 1
LOCATOR
Figure 2
INSULATION
CONDUCTOR
WIRE
TERMINAL
Figure 3
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
GRIPS
GRIPS
1. Place the terminal into the correct die profile (A or B) in the jaws of the hand tool.
2. Partially close the tool until the terminal is held in place. See Figure 1. If the insulation diameter is too large to
do this, then place the insulation down into the terminal before closing the tool.
3. Position a wire into the terminal so the wire lines up with the conductor and insulation grips visually.
4. Finish closing the hand tool until the ratchet releases. See Figure 4.
5. Then open the tool and carefully remove the crimped terminal.
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.
4. 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 lifting the ratchet release lever. See Figure 4.
Doc No: ATS-638110300 Release Date: 12-10-03 UNCONTROLLED COPY Page 3 of 5
Revision: J Revision Date: 04-14-08
Page 4
Hand Crimp Tool for 1.25mm (.049") Pitch Crimp Terminals
How to Adjust Tool Crimp Force (See Figure 4)
It may be necessary over the life of the tool to adjust tool-crimping force. Listed below are the steps required to
adjust the crimping force of the hand tool to obtain proper crimp conditions:
1. Remove the screw and washer. Located over the adjustment ring.
2. Lift the adjusting ring slightly, off the locating pin.
3. Turn the adjusting ring in the desired direction (L= less force, T= more force) to increase or decrease crimp
pressure.
4. Press the adjusting wheel flat against the tool and engage the locking pin.
5. Replace the washer and screw.
6. Check the crimp specifications after tool crimp 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 free of manufacturing defects for a period of 30 days.
Should such a defect occur, we would exchange the tool free of charge. This 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.
Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
CAUTION: Repetitive use of this tool should be avoided.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and
tooling.
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.
7. Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
Doc No: ATS-638110300 Release Date: 12-10-03 UNCONTROLLED COPY Page 4 of 5
Revision: J Revision Date: 04-14-08
Page 5
Hand Crimp Tool for 1.25mm (.049") Pitch Crimp Terminals
RATCHET
ADJUSTMENT
2
Figure 4
1
4mm Pin (2)
3
M4 X 8LG BHCS
PARTS LIST
Item Number Order Number Description Quantity
1 63811-0201
2 11-11-0324 Spring (Main) 1
3 11-11-0320 Spring (Ratchet) 1
To replace the locator assembly, the M4 x 8 long screw and the (2) 4mm pins must be removed from the tool.
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
feninfo@molex.com
Visit our Web site at http://www.molex.com
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
fesinfo@molex.com
Locator Assembly
RING
1
RELEASE LEVER
European Headquarters
Munich, Germany
49-89-413092-0
eurinfo@molex.com
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Doc No: ATS-638110300 Release Date: 12-10-03 UNCONTROLLED COPY Page 5 of 5
Revision: J Revision Date: 04-14-08
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