Molex 63819-4400 Manuel utilisateur

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals

Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 10-31-08

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

HAND CRIMP TOOL

Specification Sheet

Or er No. 63819-4400

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

 This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal, 26-28 AWG.

1.25mm (.049") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal, 26-28 AWG.

Insulation Diameter

Terminal Or er No. Wire Size IPC/WHMA-A620 Terminal Strip Length

Terminal

Series No.

Loose Piece





Reel AWG

mm² mm In. mm In. mm In.

501930-0200

501930-0100

501930 501930-1200

501930-1100

26-28

.136-.079

0.80-1.00

.032-.039

0.80-1.00

.031-.039

1.50-1.70

.059-.067

502381-0000

502381 502381-0010

26-28

.136-.079

0.80-1.00

.032-.039

0.80-1.00

.031-.039

1.50-1.70

.059-.067

Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.

To achieve optimum IPC-A620 Class 2 insulation crimps, use this insulation OD range.

Overall insulation OD specification for terminal.

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 For 1.25mm (.049") Pitch Crimp Terminals

Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 10-31-08

CONDITIONS:

After crimping, the conductor profile should measure the following.

Con uctor Profile

Wire Size Crimp Height Crimp Wi th (Ref)

501930

502381

Terminal Series No.

AWG

mm2

mm In. mm In. 26

26 0.13 0.56-0.61

.022-.024

0.80 .031 X

501930 28 0.08 0.53-0.58

.021-.023

0.80 .031 X

26 0.13 0.56-0.61

.022-.024

0.80 .031 X

502381 28 0.08 0.53-0.58

.021-.023

0.80 .031 X

Insulation (Ref)

Wire Size Crimp Height Crimp Wi th

Pull Force Minimum

Terminal Series No.

AWG

mm2

mm In. mm In. N Lb.

26 0.13 1.19-1.25

.047-.049

0.80 .031 9.8 2.20

501930 28 0.08 1.15-1.21

.045-.048

0.80 .031 9.8 2.20

26 0.13 1.18-1.28

.046-.050

0.80 .031 9.8 2.20

502381 28 0.08 1.15-1.25

.045-.049

0.80 .031 9.8 2.20

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.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals

Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 10-31-08

RELEASE

LOCATOR BUTTON

TERMINAL Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

WIRE TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE STOP IS PART OF

THE LOCATOR

Figure 5

PRE

STRIPPED

WIRE

TERMINAL

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.

ote: 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.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATC

HET

POSITION

OPEN

POSITION

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals

Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 10-31-08

Figure

PUSH ON

HANDLE

AWS OPEN

PULL OPEN

TOOLING

M3 BHCS

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.

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.

ERMINAL

Figure 6

WIRE

WIRE STOP

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SUR

CENTER OF LOCATORR

IS IN THE

DOWN POSITION

Figure 7B

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals

Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 10-31-08

Right or Left Han 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.

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.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure

RATCHET RELEASE

LEVER

Figure

MATCH

UP MARKS

FRONT

BACK

Figure

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals

Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 10-31-08

Figure 1

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

How to A just Tool Preloa (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.

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 OT 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 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 For 1.25mm (.049") Pitch Crimp Terminals

Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 10-31-08

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number Or er Number Description Quantity

REF 63819-4400 Hand Crimp Tool Figure 13

1 63819-4475 Locator Assembly 1

2 63810-0104 Spring, Return 1

3 63810-0105 Spring, Ratchet 1

Americas Hea quarters

Lisle, Illinois 60532 U.S.A.

1-800-78MOLEX

[email protected]

Far East North Hea quarters

Yamato, Kanagawa, Japan

81-462-65-2324

[email protected]

Far East South Hea quarters

Jurong, Singapore

65-6-268-6868

[email protected]

European Hea quarters

Munich, Germany

49-89-413092-0

[email protected]

Corporate Hea quarters

2222 Wellington Ct.

Lisle, IL 60532 U.S.A.

630-969-4550

Fax: 630-969-1352

Visit our Web site at http://www.molex.com

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