Molex 63819-9200 User manual

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 1 of 9

Revision: B Revision Date: 05-07-10

HAND CRIMP TOOL

Specification Sheet

Order No. 6 819-9200

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: MX150 Cable Seal Blade and Receptacle Crimp Terminals, 0.75-1.00mm2 metric and 1 -20 AWG

Wire Size and Type





Insulation Diameter

Strip Length

Terminal

Series No.

Terminal Order No. AWG mm² mm In. mm In.

TXL-1 --- 1.91-2.06 .075-.0 1

TXL-20 --- 1.70-1. 5 .067-.073

--- ISO 1.00 1.90-2.10 .075-.0 3

340 0 340 0-1002

340 0-1104

340 0-1204

--- ISO 0.75 1.70-1.90 .067-.075

TXL-1 --- 1.91-2.06 .075-.0 1

TXL-20 --- 1.70-1. 5 .067-.073

--- ISO 1.00 1.90-2.10 .075-.0 3

340 1 340 1-3004

340 1-5002

--- ISO 0.75 1.70-1.90 .067-.075

TXL-1 --- 1.91-2.06 .075-.0 1

TXL-20 --- 1.70-1. 5 .067-.073

--- ISO 1.00 1.90-2.10 .075-.0 3

340 3 340 3-3002

--- ISO 0.75 1.70-1.90 .067-.075

5.15 .203





 See crimp specification for the individual Insulation Diameter.

Terminals were validated per USCAR-21 using the following wire specifications:

M1L-123A (TXL), and M1L-126A1(metric)

TYPE 4D

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 2 of 9

Revision: B Revision Date: 05-07-10

CONDUCTOR BRUSH

STRIP LENGTH

SEAM

INSULATION CRIMP

CUT-OFF

TAB

BELL MOUTH

TWISTING

ROLLING

BEND DOWN

WIRE

SEAL

TERMINAL WIDTH NOT TO EXCEED

2.65mm AFTER CRIMPING

BEND UP

THIS AREA

ONDUCTOR

CRIMP

CONDUCTOR BRUSH

STRIP LENGTH

SEAM

INSULATION CRIMP

CUT-OFF

TAB

BELL MOUTH

TWISTING

ROLLING

BEND DOWN

WIRE

SEAL

TERMINAL WIDTH NOT TO EXCEED

2.62mm AFTER CRIMPING

BEND UP

THIS AREA

CONDUCTOR CRIMP

DEFINITION OF TERMS (Blade)

DEFINITION OF TERMS (Receptacle)

CRIMP SPECIFICATION

Bell mouth 



Conductor Brush Maximum

Terminal

Series No.

mm In. mm In.

340 0

340 1

340 3

0.30-0.70

.012-.02

0.40 .016

Not to exceed above the conductor crimp height

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 3 of 9

Revision: B Revision Date: 05-07-10

WIRE

INSULATION SEAL

0.70mm (REF)

SEAL POSTION

Bend up Bend down

Twist Roll

Terminal

Series No.

Degree Degree

340 0

340 1

340 3

3 3 3 3

Seam

Seam shall not be

open and no wire allowed

out of the crimping area

After crimping, the crimp profiles should measure the following:

Conductor

Wire Size and Type

Crimp Height Crimp Width Pull Force Minimum

Terminal Series No.

AWG mm² mm In. mm In. N Lb.

TXL-1 --- 1.20-1.30

.047-.051

2.05-2.25

.0 1-.0 9

90 20.2

TXL-20 --- 1.10-1.20

.043-.047

2.05-2.25

.0 1-.0 9

75 16.9

--- ISO 1.00 1.25-1.35

.049-.053

2.05-2.25

.0 1-.0 9

120 27.0

340 0

--- ISO 0.75 1.20-1.30

.047-.051

2.05-2.25

.0 1-.0 9

90 20.2

TXL-1 --- 1.20-1.30

.047-.051

2.05-2.25

.0 1-.0 9

90 20.2

TXL-20 --- 1.10-1.20

.043-.047

2.05-2.25

.0 1-.0 9

75 16.9

--- ISO 1.00 1.25-1.35

.049-.053

2.05-2.25

.0 1-.0 9

120 27.0

340 1

--- ISO 0.75 1.20-1.30

.047-.051

2.05-2.25

.0 1-.0 9

90 20.2

TXL-1 --- 1.20-1.30

.047-.051

2.05-2.25

.0 1-.0 9

90 20.2

TXL-20 --- 1.10-1.20

.043-.047

2.05-2.25

.0 1-.0 9

75 16.9

--- ISO 1.00 1.25-1.35

.049-.053

2.05-2.25

.0 1-.0 9

120 27.0

340 3

--- ISO 0.75 1.20-1.30

.047-.051

2.05-2.25

.0 1-.0 9

90 20.2

Insulation

Wire Size and Type





Insulation Diameter

Crimp Height Crimp Width

Terminal Series No.

AWG mm² mm In. mm In. mm In.

TXL-1 --- 1.91-2.06 .075-.0 1 3.60-3. 0

.142-.150

3.45-3.65

.136-.144

TXL-20 ---- 1.70-1. 5 .067-.073 3.50-3.70

.13 -.146

3.45-3.65

.136-.144

--- ISO 1.00 1.90-2.10 .075-.0 3 3.60-3. 0

.142-.150

3.45-3.65

.136-.144

340 0

--- ISO 0.75 1.70-1.90 .067-.075 3.50-3.70

.13 -.146

3.45-3.65

.136-.144

TXL-1 --- 1.91-2.06 .075-.0 1 3.60-3. 0

.142-.150

3.45-3.65

.136-.144

TXL-20 ---- 1.70-1. 5 .067-.073 3.50-3.70

.13 -.146

3.45-3.65

.136-.144

--- ISO 1.00 1.90-2.10 .075-.0 3 3.60-3. 0

.142-.150

3.45-3.65

.136-.144

340 1

--- ISO 0.75 1.70-1.90 .067-.075 3.50-3.70

.13 -.146

3.45-3.65

.136-.144

TXL-1 --- 1.91-2.06 .075-.0 1 3.60-3. 0

.142-.150

3.45-3.65

.136-.144

TXL-20 ---- 1.70-1. 5 .067-.073 3.50-3.70

.13 -.146

3.45-3.65

.136-.144

--- ISO 1.00 1.90-2.10 .075-.0 3 3.60-3. 0

.142-.150

3.45-3.65

.136-.144

340 3

--- ISO 0.75 1.70-1.90 .067-.075 3.50-3.70

.13 -.146

3.45-3.65

.136-.144





Cable Seal Position On a Wire

(Before crimping)

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 4 of 9

Revision: B Revision Date: 05-07-10

Wire Size and Type





Cable Seal Profile

Terminal Series No.

AWG mm² Manufacturer and Part No.

Color 18

0.75

1.00

TXL-1 --- QSR E-1644-00 Green

--- ISO 0.75 QSR E-1644-00 Green

--- ISO 1.00 QSR E-1644-00 Green

340 0

TXL-20 --- QSR E-1644-00 Green

TXL-1 --- QSR E-1644-00 Green

--- ISO 0.75 QSR E-1644-00 Green

--- ISO 1.00 QSR E-1644-00 Green

340 1

TXL-20 --- QSR E-1644-00 Green

TXL-1 --- QSR E-1644-00 Green

--- ISO 0.75 QSR E-1644-00 Green

--- ISO 1.00 QSR E-1644-00 Green

340 3

TXL-20 --- QSR E-1644-00 Green

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.

LOCATOR

IN DOWN

POSTION

PUSH ON

THE

LOCATOR

BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 5 of 9

Revision: B Revision Date: 05-07-10

Figure 4 TERMINAL

WIRE AGAINST

THE

WIRE STOP

WIRE AND SEAL

POSITION

WIRE STOP IS

PART OF THE

LOCATOR

WIRE AND SEAL

POSITIONED IN

LOWER PART OF

THE PUNCHES

TERMINAL

RELEASE LOCATOR

BUTTON

TERMINAL

Figure

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

4. Release the locator button, allowing the locator to return to the crimping position.

5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the

upper tooling, until the wire is against the wire stop. See Figure 4.

6. Seal position should be under and inside the punches, keep this position while crimping.

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.

. Remove the crimped terminal from the terminal locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper crimp location.

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.

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 6 of 9

Revision: B Revision Date: 05-07-10

Figure 6

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING TOOLING

M BHCS

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 5A 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 5A.

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 5B.

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.

Right 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 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 6 and 7.

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.

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 5B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 5A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

FRONT BACK

MATCH

UP MARKS

Figure 7

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 7 of 9

Revision: B Revision Date: 05-07-10

Figure 10

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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. See Figure .

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 9.

How to Adjust Tool Preload

(See Figure 10)

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

RATCHET RELEASE

LEVER

Figure 9

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTHS

5,000 CRIMPS)

Figure 8

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page of 9

Revision: B Revision Date: 05-07-10

(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. 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 MX150 Cable Seal Crimp Terminals

Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 9 of 9

Revision: B Revision Date: 05-07-10

Figure 11

PARTS LIST

Item Number Order Number Description Quantity

REF 63 19-9200 Hand Crimp Tool Figure 11

1 63 19-9275 Locator Assembly 1

2 63 10-0104 Spring, Return 1

3 63 10-0105 Spring, Ratchet 1

Americas Headquarters

Lisle, Illinois 60532 U.S.A.

1- 00-7 MOLEX

[email protected]

Far East North Headquarters

Yamato, Kanagawa, Japan

1-462-65-2324

[email protected]

Far East South Headquarters

Jurong, Singapore

65-6-26 -6 6

[email protected]

European Headquarters

Munich, Germany

49- 9-413092-0

[email protected]

Corporate Headquarters

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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