Molex TPX50-50 User guide

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals

Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 09-03-20

Application Tooling Specification

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

Modular crimp head is removable and can be used in the Electric Crimp Machine (Order No.

63816-1500), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

Can also be used in the Battery Powered Tool Order No. 63816-0270 (110 V) or 63816-0280

(220 V), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

SCOPE

Products: TPX50-50 Large Grip Receptacle Crimp Terminals, 0.50mm² FLR91X-A XLPO Wire.

Terminal Series

No.

Terminal Order No.

Wire

Insulation Diameter

Strip Length (Ref)

Wire Type

Wire Size

In.

201691

201691-4320

201691-4321

FLR91X-A XLPO

0.50mm2

1.40-1.60

.055-.063

3.50

.138

Order Number

213309-0500

Type 4A

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals

Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 09-03-20

DEFINITION OF TERMS

CRIMP SPECIFICATION

The following crimp specifications are based on AS document 2016910000 Rev. B3:

Feature

Requirement

1. Bend Up

1° Max

2. Bend Down

1° Max

3. Twist

2° Max

4. Roll

Not Applicable

5. Bell Mouth Rear

0.10-0.40mm (.004-.016”)

6. Bell Mouth Front

Not Applicable

7. Conductor Brush

0.30-0.70mm (.012-.028”)

8. Cut-Off Tab

0.20mm (.008”) Max, no burrs

Conductor Crimp

Wire Type

Wire Size

9. Crimp Height

10. Crimp Width (MAX)

FLR91X-A XLPO

0.50mm2

0.73-0.77mm

.029-.030 in.

1.45mm

.057 in.

Insulation Crimp

Wire Type

Wire Size

11. Crimp Height (MAX)

12. Crimp Width (MAX)

FLR91X-A XLPO

0.50mm2

1.85mm

.073 in.

1.50mm

.059 in.

Pull Force

Wire Type

Wire Size

Minimum Force

FLR91X-A XLPO

0.50mm2

75 N

16.8 lb.

To be measured with no influence

from the insulation crimp.

13. Conductor Anvil Flash

0.15mm (.006”) Max

14. Conductor Grip Step

0.01-0.21mm (.000-.008”)

15. Insulation Grip Step

0.00-0.20mm (.000-.008”) above datum D

16. Crimp Bulge

1.25mm (.049”) Max within crimp/transition area

Misc.

Wire Type

Wire Size

17. Wing Dissymmetry

18. Space Between Wing Tips

and Crimp Bottom

FLR91X-A XLPO

0.50mm2

0.00-0.10mm

.000-.004 in.

No contact

SECTION K-K

SECTION L-L

CRIMP/TRANSITION

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals

Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 09-03-20

Figure 3

WIRE

TERMINAL

LOCATOR

INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR

ANVIL

CONDUCTOR

PUNCH

WIRE STOP BLADE

WIRE

INSULATION

PUNCH

Figure 2

TERMINAL

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. It must lie between

the minimum and maximum crimp height specification.

3. 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 sheet.

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

3. This tool is intended for metric conductor sizes. 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 5. 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.

5. Conductor crimp height should be used as the final criterion for an acceptable crimp. Refer to

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

testing.

6. Molex does not certify hand crimp tools.

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.

1. With the hand tool in the open position, pivot the

terminal locator open by pulling up on the locator

knob, and lift the wire stop blade. See Figure 1.

2. Insert the terminal into the profile until the terminal is

fully seated and stops. Make sure the wire stop blade

is fully seated on the terminal behind the conductor

grip section.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP

BLADE

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals

Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 09-03-20

INCORRECT

Figure 5

CORRECT

INCORRECT

M4 BHCS

PIVOT

LOCATOR

Figure 4

5. Slide the pre-stripped wire into the terminal, making sure to aim the wire brush toward

the tip point on the wire stop blade. See Figure 2. Align the wire so that it is parallel and

sitting into the terminal. Maintain a light and constant pressure on the wire that is

seated in the terminal at all times. (Do not let go of the wire.) Be sure to hold the wire

and terminal in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Lift the wire stop blade.

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 good brush control and a consistent bell mouth, the crimping instructions must

be followed.

TERMINAL LOCATOR REPLACEMENT

This section describes the procedure for changing locators:

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Place the locator on the hand tool. Install the M4 BHCS. See Figure 4.

2. Tighten the screw just enough to hold the locator. Make sure the locator can still float freely

with hand pressure.

3. Fully insert the proper terminal into the correct profile slot until the terminal is completely

seated and stops. Then, gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place, and slowly tighten the M4 BHCS.

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals

Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 09-03-20

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 a 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 the hand tool, particularly from the crimping area. Oil transferred from

the crimping area onto certain terminations may affect the electrical characteristics of an

application.

5. When the 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 lifting the ratchet release lever. See Figure 9.

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, Molex 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 use 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.

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals

Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 09-03-20

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 plugged 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 servicing 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.

63816-0000

Hand Crimp Frame (Short)

—

63816-0050

Hand Crimp Frame (Long)

—

63816-0270

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0280

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-1500

Electric Crimp Machine

63816-0600

Battery Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Electric Crimp Machine

Figure 6

Figure 7

Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

MODULAR

CRIMP

HEAD

BATTERY

POWERED

CRIMP

ADAPTER

LOCKING

PINS

LOCKING

PINS

BATTERY

POWERED

TOOL

ELECTRIC

CRIMP

MACHINE

MODULAR

CRIMP HEAD

BATTERY

POWER CRIMP

ADAPTER

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals

Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 09-03-20

PARTS LIST

Item

Order Number

Description

Quantity

63816-0000

Hand Crimp Frame (Short)

213309-0575

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

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.

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 9

RATCHET

RELEASE LEVER

LOCATOR

M4 X 8mm

LONG BHCS

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