Hand Crimp Tool 1.25mm (.

049”) Pitch PicoBlade Receptacle Crimp Terminals

Order Number
200218-1900
Application Tooling Specification Type 4D

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
 Dies and locator from this tool can be used in the Battery Powered Tool Order No. 63816-0270
(110 V) or 63816-0280 (220 V), with the use of the 63816-0800 Crimp Head
 Many different tool kits can be used with a single Battery Powered Crimp Tool
 This tool is RoHS compliant; however, RoHS compliance is not required
 Adjustable locator provides optimum adjustment for bell mouth specification

SCOPE

Products: 1.25mm (.049") Pitch PicoBlade Receptacle Crimp Terminals, 26-32 AWG.

Terminal Order No. Wire Size Insulation Diameter Strip Length

Terminal Series No.
Loose Piece  Reel AWG mm² mm In. mm In.
50058-8100 50058-8000
50058 50058-8400 50058-8500 28-32 N/A .67-1.00 .027-.039 1.40-1.91 .055-.075
50058-8099
50079-8100 50079-8000
50079 50079-8153 50079-8053 26-28 N/A .67-1.00 .027-.039 1.40-1.91 .055-.075
50079-8099
 Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-Off Tab.
Crimp terminals to copper stranded wire only.

DEFINITION OF TERMS

BEND UP

BRUSH BELL MOUTH CONDUCTOR

CRIMP
INSULATION ROLL
CRIMP

TWIST
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.

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 Hand Crimp Tool 1.25mm (.049”) Pitch PicoBlade Receptacle Crimp Terminals

INSULATION CRIMP FORM

This crimp terminal is designed for miniaturization; therefore, each dimension of the insulation crimp
portion appears small compared to the terminal material thickness. To avoid insulation piercing the
crimp forms by the insulation barrel, coining is provided inside the insulation barrel. For this reason,
various crimp forms will occur at the tip of the insulation crimp barrel as shown below.

These crimp forms may differ completely because of a small change in the wire, insulation punch or
terminal.

These crimp forms are satisfactory for the original function of the insulation crimp portion, and it is
confirmed that all of the following forms are acceptable insulation crimps.

CONDITIONS

After crimping, the conductor profiles should measure the following:

Terminal Conductor Crimp Insulation Crimp Pull Force

Wire Size  Bell Mouth Profile
Series Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Minimum
No. AWG mm2 mm In. mm In. mm In. mm In. mm In. N Lb. A B
28 — 0.39-0.49 .015-.019 0.84 .033 1.15 .045 0.91 .036 0.05-0.30 .002-.012 9.8 2.20 X
50058 30 — 0.37-0.47 .014-.018 0.84 .033 1.15 .045 0.91 .036 0.05-0.30 .002-.012 4.9 1.10 X
32 — 0.37-0.47 .014-.018 0.84 .033 1.15 .045 0.89 .035 0.05-0.30 .002-.012 2.9 0.66 X
26 — 0.50-0.60 .020-.024 0.86 .034 1.22 .048 0.93 .037 0.05-0.30 .002-.012 9.8 2.20 X
50079
28 — 0.50-0.60 .020-.024 0.85 .033 1.20 .047 0.91 .036 0.05-0.30 .002-.012 9.8 2.20 X
 See bell mouth adjustment notes on page 3.

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 conductor crimp height measurement should be performed. It must lie between
the minimum and maximum crimp height 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.

Notes

1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for AWG conductor sizes. It may not give good insulation crimp support for
insulation sizes outside of the specified range.
4. Molex does not repair hand tools. See warranty on page 6. The replacement parts listed are the
only parts available for repair. If the handles or crimp tooling become damaged or worn, a new
tool must be purchased.
5. Conductor crimp height should be used as the final criterion for an acceptable crimp. 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. Using the tool under magnification is recommended to achieve optimal crimp quality and
consistency.

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Hand Crimp Tool 1.25mm (.049”) Pitch PicoBlade Receptacle Crimp Terminals

 Bell Mouth Adjustment Notes

The 2002181900 hand crimp tool features an adjustable locator that allows the operator to
increase or decrease the bell mouth and brush length specifications.

Note: The tool was set up in manufacturing and used to produce the included crimp samples,
but it may be necessary to adjust the tool because of variations in terminal production.

Use a 1.5mm hex wrench to adjust to bell mouth size and brush length.

The adjustment screw is accessible through the hole

in the side of the terminal locator on the back of the
hand crimp tool. See Figure 1. TERMINAL
LOCATOR
To increase bell mouth and brush length, turn the
screw clockwise.

To decrease bell mouth and brush length, turn the

screw counterclockwise.
ADJUSTMENT
HOLE

INCREASE DECREASE
Figure 1

When making an adjustment, turn the adjustment screw half a rotation or less, and then re-check
your bell mouth and brush length.

If you feel or hear a click during the rotation, you have reached the limits of the adjustment.

Once the bell mouth and brush length are properly adjusted, follow the tool operation instructions
listed below.

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Hand Crimp Tool 1.25mm (.049”) Pitch PicoBlade Receptacle Crimp Terminals

OPERATION

CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp
hardened objects because 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 2.

Crimping Terminals

1. Select the desired terminal listed in the HANDLE WILL

SPRING OPEN LOCATOR IN
preceding charts. DOWN
2. Make sure the center of the locator is in the POSTION
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 3.
3. While holding the locator button in, load
the terminal into the proper nest opening in
the locator based on the wire gauge or Figure 3
PUSH ON THE
LOCATOR BUTTON
terminal type markings on the hand SQUEEZE
tooling. See Figure 4. HANDLES
TOGETHER

LOCATOR RELEASE
Figure 2
LOCATOR LOCATOR
PUSHED BUTTON
THROUGH
TOOLING

LOCATOR
BUTTON
PUSHED IN
TERMINAL

TERMINAL Figure 4
TOOLING
4. Release the locator button, allowing the locator to return to the PARTIALLY
CLOSED
crimping position.
5. Close the tool handle until the first ratchet position engages. PARTIALLY
See Figure 5. CLOSE HANDLE
6. Insert the properly stripped wire through the terminal and
against the locator. See Figure 6.
7. Crimp the terminal by squeezing the tool handles until the
ratchet mechanism cycle has been completed. Release the
OPEN
handles to open the jaws. POSITION
LOCATOR
TERMINAL

FIRST RATCHET
PRE-STRIPPED
POSITION
WIRE
Figure 5

TERMINAL WIRE AGAINST THE LOCATOR

Figure 6

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Hand Crimp Tool 1.25mm (.049”) Pitch PicoBlade Receptacle Crimp Terminals

Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.
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 LOCATOR
wires should be inserted with the hand tool in the
open position. Insert the wire above the terminal in
the punch and against the locator, and then close
the tool. See Figure 7. TERMINAL
Figure 7

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
MAKE SURE
1. Open the crimp hand tool. CENTER OF
2. Squeeze gently on the lower area shown LOCATOR IS IN
SQUEEZE
in Figure 8A with your thumb and index THE DOWN
HERE
POSITION
finger. The lower tabs of the locator
should disengage from the hand tool.
3. Lift and pull away from the hand tool. SQUEEZE
HERE
The top locator hooks should slip out of
the top slots easily. See Figure 8A. Figure 8A
TOP SLOTS OF
4. To reinstall the new locator, make sure HAND TOOL
the hand tool is in the open position.
5. Press the red insert down as far as it will TOP HOOKS
go as shown in Figure 8B.
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’s top slots.
7. Rotate the locator down, and press the Figure 8B
lower tabs into the two bottom slots of
the hand tool. To secure the locator into
place, the lower tabs must snap into LOWER TABS
place on the hand tool frame.

Right- or Left-Handed Operation JAWS OPEN

This hand tool has an added feature that can PULL OPEN
be converted from a right-handed application TOOLING
TOOLING
to a left-handed application. It is necessary to
reverse the tooling if using the left-handed M3 BHCS
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 Figure 9
the upper tooling.
PUSH ON
HANDLE

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Hand Crimp Tool 1.25mm (.049”) Pitch PicoBlade Receptacle Crimp Terminals

3. Flip the upper tooling to the opposite side,

and replace the M3 BHCS. Make sure the
MATCH
small markings on the front and back of
UP MARKS
the hand tool frame match up and are on
the outside of the hand tool frame. See
Figures 9 and 10.
4. Do the same thing with the lower tooling, Figure 10
and tighten the M3 screws. Be sure the
small markings line up.
5. Reinstall the locator by following the
instructions in the locator replacement FRONT BACK
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 a 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 LUBRICATION POINTS
other equipment, it needs cleaning and lubrication for a maximum (BOTH SIDES) LIGHT
OIL
service life of trouble-free crimping. Light oil (such as 30 weight
(EVERY 3 MONTHS OR
automotive oil) used at the oil points every 5,000 crimps or 3 5,000 CRIMPS)
months will significantly enhance the tool life. See Figure 11.
4. Wipe excess oil from hand tool, particularly from crimping area. Figure 11
Oil transferred from the crimping area onto certain terminations
may affect the electrical characteristics of an application.
5. When the 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.

RATCHET RELEASE
Miscrimps or Jams 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 12.

Figure 12

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Hand Crimp Tool 1.25mm (.049”) Pitch PicoBlade Receptacle Crimp Terminals

How to Adjust Tool Preload (See Figure 13)

This hand tool is factory preset to 25-45 pounds 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:
SQUEEZE THE HOLD THE HAND
1. Hold the hand tool in the palm LINK IN THE TOOL IN
of your hand as shown in RATCHET HANDLE POSITION
Figure 12. Using your index RELEASE LEVER
finger, squeeze the link toward
the top of the hand tool frame.
This will release the preload
adjustment wheel.
2. Rotate the setting wheel
counterclockwise (CCW) to
increase handle force. The
numbers will display higher.
To decrease handle force,
rotate the setting wheel
clockwise (CW). Figure 13
3. Release the link to lock the
SETTING WHEEL
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, Molex 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 use 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. See the Molex website 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.

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Hand Crimp Tool 1.25mm (.049”) Pitch PicoBlade Receptacle Crimp Terminals

PARTS LIST

Item Number Order Number Description Quantity

REF 200218-1900 Hand Crimp Tool Figure 14
1 200218-1975 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1

RATCHET
RELEASE LEVER

Figure 14 3

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: applicationtooling@molex.com
Website: www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.

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