Molex 63819-4100 User manual

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal

Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 1 of 4

Revision: A Revision Date: 01-05-09

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

SEAM

HAND CRIMP TOOL

Specification Sheet

Or er No. 63819-4100

FEATURES

% A full cycle ratcheting hand tool ensures complete crimps

% Ergonomically designed soft handles

% Precisely designed crimping profiles with simple contact positioning

% Easy handling due to outstanding force ratio

% A-620 Class 2 compliant

% RoHS compliant although not required

SCOPE

Products: CTX 1.50mm Receptacle Crimp Terminal for 1.25, 1.50, and 2.00mm2 wires.

Terminal Or er No. Wire Size Insulation Diameter Wire Strip Length Terminal

Series Reel Form only Wire Style mm2 / AWG mm In. mm In.

AVSS 1.25

ISO 1.50

AVSS 2.00

502307

502307-0113

502307-1113

502307-2113

502307-0123

502307-1123

502307-2123 ISO 2.00

2.10-2. 0 .0 3-.110 4.50-5.00 .177-.197

Customer to cut off terminal from reel: 0.30mm (.012”) 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 4A

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal

Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 2 of 4

Revision: A Revision Date: 01-05-09

CONDITIONS:

Bell mouth Con uctor Brush Ben up Ben Down Twist Roll

Terminal

Series mm In. mm In. Degree Degree

502307 0.20-0.55 .00 -.022 0.20-0.70 .00 -.02 1.5 1.5 4 6

After crimping, the crimp profiles should measure the following (See notes on page 4).

Con uctor Crimp Reference Profile

Wire Size Height Punch Wi th

1.25mm2

1.50mm2

2.0mm2

Terminal

Series No.

Wire Style

mm2 / AWG

mm In. mm In. A B C

AVSS 1.25 1.20-1.30

.047-.051

2.20 .0 7 X

ISO 1.50 1.30-1.40

.051-.055

2.20 .0 7 X

ISO 2.00 1.45-1.55

.057-.061

2.20 .0 7 X

502307

AVSS 2.00 1.50-1.60

.059-.063

2.20 .0 7 X





Insulation Crimp Reference

Wire Size Height Maximum

Wi th Maximum

Pull Force

Minimum

Terminal

Series No.

Wire Style

mm2 / AWG

mm In. mm In. N Lb.

AVSS 1.25 2.60 .102 2. 0 .110 1 0.0

40.5

ISO 1.50 2. 0 .110 2. 0 .110 155.0

34.9

ISO 2.00 2. 0 .110 2. 0 .110 245.0

55.1

502307

AVSS 2.00 2. 0 .110 2. 0 .110 245.0

55.1





 Insulation crimp should meet IPC/WHMA-A-620 Class 2 compliance.

Pull Force should be measured with no influence from the insulation crimp.

The above specifications are guidelines to an optimum crimp.

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 the wire stop blade up.

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 into the wire stop blade. See

Figure 1. Be sure to hold the wire in place until the terminal is fully crimped. See Figure 2.

5. Close the tool until the ratchet releases, the tool handles will then spring open.

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

7. Carefully remove the crimped terminal.

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

followed.

TERMINAL

PRE

STRIPPED

WIRE

LOCATOR

Figure 1

WIRE STOP

BLADE

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal

Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 3 of 4

Revision: A Revision Date: 01-05-09

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.

4. 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 (See Figure 3)

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 pushing the ratchet release lever.

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

ays. Should such a defect occur, we would exchange the tool free of charge. This 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.

Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable. Variations in tools, terminals, and wire stranding and insulation types may affect

crimp height.

3. This tool is intended only for the wire types specified. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips on

the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping Handbook

63 00-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and

tooling.

Figure 2

CONDUCTOR

PUNCH

WIRE

LOCATOR

TERMINAL

INSULATION

PUNCH

INSULATION

ANVIL

CONDUCTOR

ANVIL

WIRE STOP

BLADE

RETAINER

SPACER

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal

Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 4 of 4

Revision: A Revision Date: 01-05-09

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure3

M4 X 14mm

LONG BHCS

M4 FLAT

WASHER

PARTS LIST

Item Number

Or er Number

Description Quantity

1 63600-0520 Crimping Spring

2 63600-0525 Handle Spring 1

3 63 11-4175 Locator 1

Americas Hea quarters

Lisle, Illinois 60532 U.S.A.

1- 00-7 MOLEX

[email protected]

Far East North Hea quarters

Yamato, Kanagawa, Japan

1-462-65-2324

[email protected]

Far East South Hea quarters

Jurong, Singapore

65-6-26 -6 6

[email protected]

European Hea quarters

Munich, Germany

49- 9-413092-0

[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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