hand crimp tool for 1.25mm (.049") pitch crimp terminals doc no: ats-638194400 release date: 10-31-08 uncontrolled copy page 1 of 7 revision: a revision date: 10-31-08 insulation crimp brush strip length bell mouth crimp height bend down bend up rolling conductor crimp twisting hand crimp tool specification sheet order no. 63819-4400 features a full cycle ratcheting hand tool ensures complete crimps ergonomic soft grip handles for comfortable crimpin g a precision user-friendly terminal locator wire sto p 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 : 1.25mm (.049") pitch wire-to-board crimp terminal , 26-28 awg. 1.25mm (.049") pitch clik-mate? wire-to-board crimp terminal, 26-28 awg. insulation diameter terminal order no. wire size ipc/whma-a620 terminal strip length terminal series no. loose piece reel awg mm2 mm in. mm in. mm in. 501930-0200 501930-0100 501930 501930-1200 501930-1100 26-28 .136-.079 0.80-1.00 .032-.039 0.80-1.00 .031-.039 1.50-1.70 .059-.067 502381-0000 502381 502381-0010 26-28 .136-.079 0.80-1.00 .032-.039 0.80-1.00 .031-.039 1.50-1.70 .059-.067 customer to cut off terminal from reel: 0.15mm (.00 6) maximum cut-off tab. to achieve optimum ipc-a620 class 2 insulation crim ps, use this insulation od range. overall insulation od specification for terminal. definition of terms the above terminal drawing is a generic terminal re presentation. it is not an image of a terminal lis ted in the scope. type 4d
hand crimp tool for 1.25mm (.049") pitch crimp terminals doc no: ats-638194400 release date: 10-31-08 uncontrolled copy page 2 of 7 revision: a revision date: 10-31-08 conditions: after crimping, the conductor profile should measur e the following. conductor profile wire size crimp height crimp width (ref) 501930 502381 terminal series no. awg mm 2 mm in. mm in. 26 28 26 28 26 0.13 0.56-0.61 .022-.024 0.80 .031 x 501930 28 0.08 0.53-0.58 .021-.023 0.80 .031 x 26 0.13 0.56-0.61 .022-.024 0.80 .031 x 502381 28 0.08 0.53-0.58 .021-.023 0.80 .031 x insulation (ref) wire size crimp height crimp width pull force minimum terminal series no. awg mm 2 mm in. mm in. n lb. 26 0.13 1.19-1.25 .047-.049 0.80 .031 9.8 2.20 501930 28 0.08 1.15-1.21 .045-.048 0.80 .031 9.8 2.20 26 0.13 1.18-1.28 .046-.050 0.80 .031 9.8 2.20 502381 28 0.08 1.15-1.25 .045-.049 0.80 .031 9.8 2.20 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. a t the end of the closing stroke, the ratchet mechanism will release the hand les 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. squeeze handles together handle will spring open figure 1 locator in down postion push on the locator button figure 2
hand crimp tool for 1.25mm (.049") pitch crimp terminals doc no: ats-638194400 release date: 10-31-08 uncontrolled copy page 3 of 7 revision: a revision date: 10-31-08 release locator button terminal figure 3 locator pushed thru tooling terminal locator button pushed in locator wire terminal wire against the wire stop wire stop is part of the locator figure 5 pre - stripped wire terminal 4. release the locator button, allowing the locator to return to the crimping position. 5. close the tool handle until the first ratchet posit ion engages. see figure 4. 6. insert the properly stripped wire through the termi nal and against the wire stop. see figure 5. 7. crimp the terminal by squeezing the tool handles un til the ratchet mechanism cycle has been completed. release the ha ndles to open the jaws. note: the tamper proof ratchet action will not rele ase the tool until it has been fully closed. 8. remove the crimped terminal from the terminal locat or by pulling on the wire. 9. visually inspect the crimped terminal for proper cr imp location. partially close handle tooling partially closed figure 4 first ratc het position open position
hand crimp tool for 1.25mm (.049") pitch crimp terminals doc no: ats-638194400 release date: 10-31-08 uncontrolled copy page 4 of 7 revision: a revision date: 10-31-08 figure 8 push on handle aws open pull open tooling tooling m3 bhcs 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. note: a crimp height chart is provided with this manual a s 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 fo rce test should be performed to check hand tool crimp. pull force value must exceed the minimum pull force specifications listed. locator replacement see the parts list on the last page of this documen t 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 7a 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 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 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. t erminal figure 6 wire wire stop squeeze here squeeze here locator figure 7a top hooks top slots of handtool lower tabs make sur e center of locatorr is in the down position figure 7b
hand crimp tool for 1.25mm (.049") pitch crimp terminals doc no: ats-638194400 release date: 10-31-08 uncontrolled copy page 5 of 7 revision: a revision date: 10-31-08 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 tooli ng. 3. flip the upper tooling to the opposite side and rep lace 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 t ool frame. see figure 8 and 9. 4. do the same thing with the lower tooling and tighte n the m3 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. 3. make certain all pins; pivot points and bearing sur faces are protected with a thin coat of high quality machine oil. do n ot oil excessively. the tool was engineered for durability but like any oth er 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 signif icantly enhance the tool life. 4. wipe excess oil from hand tool, particularly from c rimping area. oil transferred from the crimping area onto certain ter minations 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 crimpi ng dies, and store the tool in a clean, dry area. miscrimps or jams should this tool ever become stuck or jammed in a p artially closed position, do not force the handles open or closed. the tool will open easily by pressing up on the rat chet release lever in the movable handle. see figu re 11. lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 10 ratchet release lever figure 11 match up marks front back figure 9
hand crimp tool for 1.25mm (.049") pitch crimp terminals doc no: ats-638194400 release date: 10-31-08 uncontrolled copy page 6 of 7 revision: a revision date: 10-31-08 figure 1 2 squeeze the link in the handle hold the hand tool in position setting wheel ratchet release lever 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 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 h igher. to decrease handle force rotate the setting wheel c lockwise (cw). 3. release the link to lock the setting wheel in place . 4. check the crimp specifications or conduct a pull te st after tool handle preload force is adjusted. warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life tested. all tools are war ranted to be free of manufacturing defects for a pe riod of 30 days. should such a defect occur, we will repair o r exchange the tool free of charge. this repair or exchange will not be applicable to altered, misused, or damaged t ools. this tool is designed for hand use only. an y clamping, fixturing, or use of handle extensions voids this w arranty. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling. cautions: 1. manually powered hand tools are intended for low vo lume 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 custo mers 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 t est rerun, (see how to adjust preload). % when the hand tool is no longer capable of achievin g minimum pull force, it should be taken out of ser vice and replaced.
hand crimp tool for 1.25mm (.049") pitch crimp terminals doc no: ats-638194400 release date: 10-31-08 uncontrolled copy page 7 of 7 revision: a revision date: 10-31-08 ratchet release lever 2 figure 13 1 3 parts list item number order number description quantity ref 63819-4400 hand crimp tool figure 13 1 63819-4475 locator assembly 1 2 63810-0104 spring, return 1 3 63810-0105 spring, ratchet 1 americas headquarters lisle, illinois 60532 u.s.a. 1-800-78molex amerinfo@molex.com far east north headquarters yamato, kanagawa, japan 81-462-65-2324 feninfo@molex.com far east south headquarters jurong, singapore 65-6-268-6868 fesinfo@molex.com european headquarters munich, germany 49-89-413092-0 eurinfo@molex.com 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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