Molex 63819-1500 User manual

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal

Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 1 of 7

Revision: C Revision Date: 05-22-13

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

OLLING

CONDUCTOR

CRIMP

TWISTING

Hand Crimp

Tool

Application Toolin

Specification Sheet Order No. 63819-1500

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: 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal, 28-32 AWG.

Terminal Series No.

Terminal Order No.

Wire Size

Insulation Diamet

Strip Len th

Loose Piece



Reel

AWG

mm²

In.

501193

0100

501193

0000

501193

3000

28-32

0.08-0.04

0.80-0.56

.031-.022

1.00-1.30

.039-.051

501193

2100

501193

0099

501193

3100

501193

2000

501334

0100

501334

0000

501334

2000

0.08

0.04

0.80

0.56

.031

.022

1.00

1.30

.039

.051



Customer to cut off terminal from reel: 0.

mm (.00

”) 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 For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal

Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 2 of 7

Revision: C Revision Date: 05-22-13

RELEASE

LOCATOR BUTTON

TERMINAL Fi ure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal

Series No.

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum Profile

Hei ht (Ref.)

Width (Ref.)

Hei

ht (Ref.)

Width (Ref.)

AWG

In.

Lb.

501193

0.08

0.44

0.48

.0173

.01

0.70

.028

1.00

.039

0.70

.028

9.8

2.20

0.05

0.40

0.44

.0157

.0173

0.70

.028

0.95

.037

0.70

.028

4.9

1.10

0.04

0.39

0.43

.0153

.017

0.70

.028

0.90

.035

0.70

.028

3.4

0.76

501334

0.08

0.44

0.48

.0173

.01

0.70

.028

1.00

.039

0.70

.028

9.8

2.20

0.05

0.40

0.44

.0157

.0173

0.70

.028

0.95

.037

0.70

.028

4.9

1.10

0.04

0.39

0.43

.0153

.017

0.70

.028

0.90

.035

0.70

.028

3.4

0.76

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.

Crimpin 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

Fi ure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Fi ure 1

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal

Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 3 of 7

Revision: C Revision Date: 05-22-13

PRE

STRIPPED

WIRE

TERMINAL

Fi ure 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

Fi ure 6

WIRE

WIRE STOP

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Fi ure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal

Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 4 of 7

Revision: C Revision Date: 05-22-13

Fi ure

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

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 7 .

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.

Ri ht 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 HCS which is holding the upper

tooling.

3. Flip the upper tooling to the opposite side and

replace the M3 HCS. 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

Fi ure 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Fi ure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal

Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 5 of 7

Revision: C Revision Date: 05-22-13

MATCH

UP MARKS

FRONT

BACK

Fi ure 9

4. Do the same thing with the lower tooling and tighten

the M3 screws. e 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 Fi ure 12)

This hand tool is factory preset to 25-45 L S. 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)

Fi ure 10

RATCHET RELEASE

LEVER

Fi ure 11

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal

Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 6 of 7

Revision: C Revision Date: 05-22-13

Fi ure 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 For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal

Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 7 of 7

Revision: C Revision Date: 05-22-13

RATCHET

RELEASE LEVER

Fi ure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63819

500

Hand Crimp Tool

Figure 13

63819

575

Locator Assembly

63810

0104

Spring, Return

63810

0105

Spring, Ratchet

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

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