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Hand Crimp Tool Open Barrel Terminals 

Doc No: ATS-638111000 

Release Date: 06-29-12 

Page 2 of 4 

Revision: B 

Revision Date: 10-22-12 

INSULATION 

CRIMP 

 

BRUSH 

STRIP 

LENGTH 

BELL MOUTH 

CRIMP HEIGHT 

BEND 

DOWN 

BEND UP 

ROLLING 

CONDUCTOR 

CRIMP 

TWISTING 

 

DEFINITION OF TERMS 

 
 
 
 
 
 
 
 
 
 
 
 
 
The illustration above is a generic representation of crimp attributes and not an exact image of a particular terminal. 
 

OPERATION 

 

CAUTION

: Install only Molex terminals listed above with this tool.  Do not crimp hardened objects as damage 

can occur to the tool.  

 

WARNING

: Make sure that the wire is 

DISCONNECTED

 from any power supply 

 

Make sure work area is clean and dry and wear approved eye protection. 

 

Crimping Terminals 

 
1.

 

Select the appropriate Molex terminal. 

2.

 

Verify that the wire size, terminal material thickness and conductor barrel length are within the specifications 
for this tool. 

3.

 

Strip the wire to the proper strip length. 

4.

 

Open the tool handles and insert the conductor grip area of the terminal into the desired conductor profile. See 
Figure 1. 

5.

 

Squeeze the tool handles together enough to allow the terminal barrel to touch the top of the profile radii.  

6.

 

Align the insulation edge between the conductor and insulation 
barrel and then insert the stripped wire into the terminal. 

7.

 

Verify that the conductor brush is present.  If the wire does not fit 
into the terminal, the conductor profile selection may be too 
narrow.  

8.

 

Holding the wire in place, squeeze the tool handles firmly 
together. Use two hands, if necessary. 

9.

 

After crimping, if any strands of wire are visible at the top of the 
crimp form, the conductor profile selection chosen may be too 
wide 

10.

 

Open the tool handles and insert the terminal into the desired 

insulation section. Evaluate the housing opening before 
crimping the insulation. See Figure 2.  

Figure 2 

INSULATION 

PUUNCH 

TERMINAL 

WIRE 

Summary of Contents for ServiceGrade

Page 1: ...m in N Lb 14 2 00 2 30 2 50 091 098 222 6 50 0 16 1 30 2 00 2 30 079 091 133 5 30 0 18 0 80 1 60 2 00 063 079 89 0 20 0 20 0 50 1 40 1 80 055 071 57 9 13 0 22 0 35 1 40 1 60 055 063 35 6 8 0 24 0 20 1 40 1 40 055 055 22 2 5 0 Each application should be verified for pull force Insulation Diameter Range Insulation Tool Section Range mm in mm in 3 50 3 99 138 0 157 3 90 4 80 154 189 3 00 3 50 118 0 1...

Page 2: ...hin the specifications for this tool 3 Strip the wire to the proper strip length 4 Open the tool handles and insert the conductor grip area of the terminal into the desired conductor profile See Figure 1 5 Squeeze the tool handles together enough to allow the terminal barrel to touch the top of the profile radii 6 Align the insulation edge between the conductor and insulation barrel and then inser...

Page 3: ...ed to prevent objects from becoming lodged in the crimping dies and store the tool in a clean dry area Warranty This tool is for electrical terminal crimping purposes only All tools are warranted to be free of manufacturing defects for a period of 30 days Should such a defect occur the tool will be repaired or exchanged free of charge This exchange will not be applicable to altered misused or dama...

Page 4: ...ir 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 When the hand tool is no longer capable of achieving mini...

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