Molex 63819-3500 User manual

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 1 of 6

Revision: D Revision Date: 06-30-23

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAL

Order Number

63819-3500

Application Tooling

Specification Sheet

FEATURES

A full cycle ratcheting hand tool ensures complete crimps.

Ergonomically designed soft handles for comfortable crimping.

Right- and left-handed applications.

Precisely designed crimping profiles with simple contact positioning.

Easy handling due to outstanding force ratio.

A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position.

Tooling can be installed in the 63816-1950 Power Crimp Adapter, which is installed into the 63816-0270 (110 V)

or 63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine.

This tool is RoHS compliant; however, RoHS compliance is not required.

SCOPE

Products: CP 2.8 receptacle for 1.0mm2type ID and IR wire with 2.80mm (.110"), CMC Wire Seal Receptacle,

Red.

Terminal Series No.

Terminal Order No.

Wire Size and Type

Insulation Diameter

Strip Length

Available in Reel only

AWG

mm²

In.

98910

98910-1049

98910-1149

1.0 Type

ID and IR

1.75-2.15

.069-.085

4.90-5.10

.193-.201

98910-2049

98910-2149

64324

64324-1049

64324-1149

64324-2049

64324-2149

Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.

DEFINITION OF TERMS

TYPE 4A

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 2 of 6

Revision: D Revision Date: 06-30-23

CRIMP SPECIFICATION

Terminal Series No.

Bell Mouth

Bend up Bend down

Twist Roll

Conductor Brush

In.

Degree

In.

98910

0.1-0.5

.004-.020

0.2 - 0.6

.008-.024

64324

0.1-0.5

.004-.020

0.2 - 0.6

.008-.024

Seam: Seam shall not be open, and no wire allowed out of the crimping area.

After crimping, the conductor profiles should measure the following (See notes below).

Terminal

Series No.

Wire Size

Conductor

Insulation

Pull Force

Minimum

Crimp Height

(Ref)

Crimp Width

(Ref)

Crimp Height

(Ref)

Crimp Width

(Ref)

AWG

mm2

In.

98910

1,0

1.25-1.35

.049-.053

2.07

.081

4.60-4.80

.181-.189

5.00

.197

115

25.8

64324

1,0

1.25-1.35

.049-.053

2.07

.081

4.60-4.80

.181-.189

5.00

.197

115

25.8

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, and it should be used as the final

criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification.

Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp

testing.

3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force

specification. 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 document.

2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.

3. This tool is intended for the conductor sizes specified on this document. 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 4. 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.

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

can occur to the tool or die.

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 3 of 6

Revision: D Revision Date: 06-30-23

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

1. Lift up the wire stop blade.

2. Insert the terminal fully into the correct profile until the terminal

is fully seated and stops.

3. Bring down the wire stop blade.

4. Slide the pre-stripped wire with the seal into the wire stop

blade. See Figure 1.

5. Be sure to hold the wire in place until the terminal is fully crimped. See Figure 2.

6. Close the tool until the ratchet releases. The tool handles will then spring open.

7. Lift up the wire stop blade if it is still in down position.

8. Carefully remove the crimped terminal.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Note: To maintain a good brush control and a consistent bell mouth the crimping instructions must be followed.

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 weights 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.

Figure 2

CONDUCTOR

PUNCH

WIRE

LOCATOR

TERMINAL

INSULATION

PUNCH

INSULATION ANVIL

CONDUCTOR

ANVIL

WIRE STOP

BLADE

SEAL

TERMINAL

PRE-STRIPPED

WIRE WITH SEAL

Figure 1

WIRE STOP

BLADE

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 4 of 6

Revision: D Revision Date: 06-30-23

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 6.

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: Repetitive use of this tool should be avoided.

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.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

CERTIFICATION

Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for

customers to re-certify hand tools or determine tool life:

When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out

of service and replaced.

The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 5 of 6

Revision: D Revision Date: 06-30-23

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

APPLICATIONS FOR THE MODULAR CRIMP HEAD

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.

CAUTION: Wear safety glasses when operating or serving this tool.

The chart below shows all applications for this Modular Crimp Head.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63819-3500

Hand Crimp Tool

---

63816-0270

Battery Power Tool (110 V)

63816-1950

Battery Power Crimp Adapter

63816-0280

Battery Power Tool (220 V)

63816-1950

Battery Power Crimp Adapter

63816-1900

Electric Crimp Machine

63816-1950

Battery Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Electric Crimp Machine

Figure 3

Figure 4

Figure 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME

ELECTRIC

CRIMP

MACHINE

INSTALL BATTERY

POWERED ADAPTER WITH

CRIMP HEAD HERE

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 6 of 6

Revision: D Revision Date: 06-30-23

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 6

M4 X 14mm

LONG BHCS

M4 FLAT

WASHER

PARTS LIST

Hand Crimp Tool 63819-3500

Item

Order Number

Description

Quantity

REF

63819-3500

Hand Crimp Tool

Figure 6

---

Hand Crimp Frame

---

Modular Crimp Head

63819-3575

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Application Tooling Support

E-Mail: [email protected]m

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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