Molex 63819-1300 Bedienungsanleitung

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 1 of 9

Revision: F Revision Date: 08- 1-12

Hand Crimp

Tool

Application Tooling

Specification Sheet Order No. 3819-1300

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 WHMA-IPCA620 Class 2 compliant as indicated

 This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: 1.57mm (.062") Diameter, Standard .062" Pin and Socket Crimp Terminals, 18-24 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size







Insulation Diameter

Strip Length

Loose Piece



Reel

AWG

mm²

In.

1560

210

6119

2101

6118

18-24

0.82-0.20

1.52- .05 .060-.120 2.41- .04

.095-.120

6102

0805

6100

0278

610

0 27

6101

0 28

6104

0 0

6105

0 29

6112

6116

1561

110

0808

1101

0806

18-24

0.82-0.20

1.52- .05 .060-.120 2.41- .04

.095-.120

5102

0 1

1118

0279

510

0 4

5100

0 2

5104

5101

5109

5108

1786

2202

6202

2201

6201

0.82

0.20

1.52

.05

.060

.120

2.41

.04

.095

.120

1787

1202

1201

5205

18-24

0.82-0.20

1.52- .05 .060-.120 2.41- .04

.095-.120

5201

5005

0042

1012

0001

1011

0.82

0.20

1. 0

.00

.051

.118

2. 0

2.95

.090

.116

5006

004

1014

0002

101

0.82

0.20

1. 0

.00

.051

.118

2. 0

2.95

.090

.116



Customer to cut off terminal from reel: 0.1 mm (.005”) maximum Cut

off Tab.



See Conditions on page .

TYPE 4D

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 2 of 9

Revision: F Revision Date: 08- 1-12

INSULATION CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the

scope.

CRIMP SPECIFICATIONS

After crimping, the crimped terminals should measure as follows:

Terminal

Series No

Wire Size

Conductor Crimp

Insulation Crimp

Height (Ref.)

Width (Ref.)

Height (Ref.)

Width (Ref.)

AWG

In.

1560

0.82

0.87

0.97

.0 4

.0 8

1.66

.065

2.62

.10

2.47

.097

0.52

0.85

0.95

.0 7

1.65

.065

2.60

.102

2.46

.096

0. 2

0.82

0.92

.0 2

.0 6

1.50

.059

2.20

.087

2.2

.088

0.20

0.77

0.87

.0 0

.0 4

1.50

.059

2.12

.08

2.20

.087

1561

0.82

0.87

0.97

.0 4

.0 8

1.66

.065

2.62

.10

2.47

.097

0.52

0.85

0.95

.0 7

1.65

.065

2.60

.102

2.46

.096

0. 2

0.82

0.92

.0 2

.0 6

1.50

.059

2.20

.087

2.2

.088

0.20

0.77

0.87

.0 0

.0 4

1.50

.059

2.12

.08

2.20

.087

1786

0.82

0.87

0.97

.0 4

.0 8

1.66

.065

2.62

.10

2.47

.097

0.52

0.85

0.95

.0 7

1.65

.065

2.60

.102

2.46

.096

0. 2

0.82

0.92

.0 2

.0 6

1.50

.059

2.20

.087

2.2

.088

0.20

0.77

0.87

.0 0

.0 4

1.50

.059

2.12

.08

2.20

.087

1787

0.82

0.87

0.97

.0 4

.0 8

1.66

.065

2.62

.10

2.47

.097

0.52

0.85

0.95

.0 7

1.65

.065

2.60

.102

2.46

.096

0. 2

0.82

0.92

.0 2

.0 6

1.50

.059

2.20

.087

2.2

.088

0.20

0.77

0.87

.0 0

.0 4

1.50

.059

2.12

.08

2.20

.087

5005

0.82

0.94

1.04

.0 7

.041

1.68

.066

2.65

.104

2.54

1.00

0.52

0.91

1.01

.0 6

.040

1.67

.065

2.58

.102

2.48

.098

0. 2

0.86

0.96

.0 4

.0 8

1.5

.060

2.27

.089

2.29

.090

0.20

0.84

0.94

.0 7

1.52

.059

2.20

.079

2.22

.087

5006

0.82

0.94

1.04

.0 7

.041

1.68

.066

2.65

.104

2.54

1.00

0.52

0.91

1.01

.0 6

.040

1.67

.065

2.58

.102

2.48

.098

0. 2

0.86

0.96

.0 4

.0 8

1.5

.060

2.27

.089

2.29

.090

0.20

0.84

0.94

.0 7

1.52

.059

2.20

.079

2.22

.087

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page of 9

Revision: F Revision Date: 08- 1-12

Terminal Series No

Wire Size

PULL Force

Min

imum



Profile

AWG

Lb.

1560

0.82

20.00

0.52

66.8

15.00

0. 2

44.5

10.00

0.20

5.6

8.00

1561

0.82

20.00

0.52

66.8

15.00

0. 2

44.5

10.00

0.20

5.6

8.00

1786

0.82

20.00

0.52

66.8

15.00

0. 2

44.5

10.00

0.20

5.6

8.00

1787

0.82

20.00

0.52

66.8

15.00

0. 2

44.5

10.00

0.20

5.6

8.00

5005

0.82

98.0

22.00

0.52

66.8

15.00

0. 2

5 .4

12.00

0.20

5.6

8.00

5006

0.82

98.0

22.00

0.52

66.8

15.00

0. 2

5 .4

12.00

0.20

5.6

8.00

 To Achieve IPC-A- 20 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:

1. Profile 18-20: 1.70mm – 2. 0mm (.067 -.091 inch)

2. Profile 22-24: 1.85mm – 2. 0mm (.07 -.091 inch)

CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as

damage can occur to the tool frame and/or crimp dies.

▲Insulation Crimp Note:

Due to the terminal’s insulation grip design and/or

insulation diameter range, this tool uses “overlap”

form geometry in the insulation punch. This produces

an overlap insulation crimp (A620 – compliant). While

the insulation punch profile may appear “lopsided”,

this is a normal condition for this tool. See figure to

the right.





 Tool Qualification Notes:

1. Pull Force should be measured with no influence

from the insulation crimp.

2. The above specifications are guidelines to an

optimum crimp.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 4 of 9

Revision: F Revision Date: 08- 1-12

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

TERMINAL Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

RELEASE

LOCATOR

BUTTON

LOCATOR

BUTTON

PUSHED IN

LOCATOR IN

DOWN POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

Note:

A crimp height chart is provided with this manual as Reference Only. Due to the

wide range of wires, strands, insulation diameters, and durometer 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 specification.

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.

See Figure 1.

Crimping Terminals

1. Select the desired terminal from the chart, and install the proper locator (See

chart above and Locator Installation on page 5).

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.

. While holding in the locator button, 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 .

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.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 5 of 9

Revision: F Revision Date: 08- 1-12

Figure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS

PART OF THE

LOCATOR

PRE

STRIPPED

WIRE

TERMINAL

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.

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.

TERMINAL

Figure

WIRE

WIRE STOP

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

SQUEEZE

HERE

LOCATOR

Figure 7A

SQUEEZE

HERE

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 6 of 9

Revision: F Revision Date: 08- 1-12

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.

. 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 7B.

6. Holding onto the lower part of the locator with your thumb and index finger, insert the locator 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

along with the locator if using the left handed application. Follow the steps

below:

1. The locator must be removed before reversing the tooling.

2. Remove the M BHCS which is holding the upper tooling.

. Flip the upper tooling to the opposite side and replace the M 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 8 and 9.

4. Do the same thing with the lower tooling and tighten the M screws. Be

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.

. 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 0 weight

automotive oil) used at the oil points, every 5,000 crimps or 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.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

MATCH

UP MARKS

FRONT

BACK

Figure 9

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 7 of 9

Revision: F Revision Date: 08- 1-12

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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

How to Adjust Tool Preload

(See Figure 12)

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 12. 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 (CW).

. 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 0 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.

RATCHET RELEASE

LEVER

Figure 11

Hand Crimp Tool For Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 8 of 9

Revision: F Revision Date: 08- 1-12

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.

. 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 Standard .062" Pin and Socket Crimp Terminals

Doc No: ATS-6 8191 00 Release Date: 01-22-08 UNCONTROLLED COPY Page 9 of 9

Revision: F Revision Date: 08- 1-12

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

6 819

Hand Crimp Tool

Figure 1

6 819

Locator Assembly (Red)

6 810

0104

Spring, Return

6 810

0105

Spring, Ratchet

http://www.molex.com

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