molex 44262-4306 User manual

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 1 of 8
Revision: E Revision Date: 06-30-23
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
Order Number
63819-5500
Application Tooling
Specification Sheet
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
Right- and left-handed applications
Easy handling due to outstanding force ratio
A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position
This tool is IPC/WHMA-A-620 compliant
Tooling can be installed in the 63816-1915 Power Crimp Head, which is installed into the 63816-0270 (110 V) or
63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: 9.14mm (.360") Pitch Crimp Terminal, Power Contact, 14-16, (2) 16 and (2)18 AWG.
Terminal Series No.
Terminal Order No.
Available in Reel form only
Wire Size
Strip Length
AWG
mm²
mm
in
44262
44262-4306
44262-4536
44262-6400
44262-6412
14-16,
(2) 16
and
(2) 18
2.00-1.30,
(2) 1.30
and
(2) 0.80
6.35
.25
44262-4336
44262-4606
44262-6401
44262-6420
44262-4406
44262-4636
44262-6402
44262-6421
44262-4436
44262-6410
44262-6422
44262-4506
44262-6411
173693
173693-4636
14-16,
(2) 16
and
(2) 18
2.00-1.30,
(2) 1.30
and
(2) 0.80
6.35
.25
The terminals above are reeled parts only. Customer to cut off terminal from reel 0.40mm (.016”) maximum.
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 4C

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 2 of 8
Revision: E Revision Date: 06-30-23
CONDITIONS:
After crimping, the conductor profiles should measure the following (See notes below).
Terminal Series No.
Wire Size
Conductor
Pull Force
Minimum
Profile
Crimp Height (Ref)
Punch Width (Ref)
AWG
mm2
mm
In.
mm
In.
N
Lb.
14 &
(2) 16
16
(2) 18
44262
173693
14
2.00
2.60-2.70
.102 -.106
4.00
.158
222
50
X
(2) 16
(2) 1.30
2.60-2.70
.102 -.106
4.00
.158
133
30
X
16
1.30
2.45-2.55
.096 -.100
4.00
.158
133
30
X
(2) 18
(2) 0.80
2.55-2.65
.100 -.104
4.00
.158
89
20
X
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, and it should be used as the final
criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification.
Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force
specification. 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 document.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for the conductor sizes specified on this document. 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 6. 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.
CAUTION: Crimp only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 3 of 8
Revision: E Revision Date: 06-30-23
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
INSTALLATION
To install the Tool Kit into the Power Crimp Head, follow the steps below:
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
To install the locator
1. Position the locator with the
hole over the brass pivot
shaft, and snap it into place.
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL
IN PLACE
Figure 3
LOCATOR LATCH
IN OPEN POSITION

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 4 of 8
Revision: E Revision Date: 06-30-23
Figure 5
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Figure 4
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCK IN
UP RIGHT
POSITION
To remove the locator
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
3. Firmly press down on the brass pivot shaft with your thumb while pulling the locator up. Slip the locator off of
the top of the brass pivot shaft.
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.
Figure 6
WIRE
CONDUCTOR ANVIL
LOCATOR
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 5 of 8
Revision: E Revision Date: 06-30-23
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
2. Swing the terminal locator away from the crimp tool shown in Figure 3. Some terminals with large insulation
grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be
loaded into the locator in the closed crimp position. See Figure 4.
3. Press down on the wire stop on the locator as shown in Figure 4. Insert the proper terminal into the proper
nest opening. Make sure when choosing the nest opening that it will correspond with the 14 & (2)16, 16 or
(2)18 profile on the hand tool. See Figure 5.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Gently touch the wire stop with the end of the wire.
See Figure 5 and 6.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.
7. Remove the crimped terminal from the
terminal locator by pressing down on the
wire stop and gently pulling on the wire. The
terminal locator can be in either position.
8. Visually inspect the crimped terminal for
proper crimp location.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the
terminal to the wire.
2. Remove the crimped terminal from the
terminal locator by pressing down on the
wire stop and gently pulling on the wire. The
terminal locator can be in either position.
3. Visually inspect the crimped terminal for proper crimp location.
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.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A
Figure 7B

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 6 of 8
Revision: E Revision Date: 06-30-23
3. Make certain all pins, pivot points and bearing surfaces in the tool head are protected with a thin coat of high-
quality machine oil. Do not oil excessively. This tool was engineered for durability, but like any fine piece of
equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. The use of
light oil such as 30 weight automotive oil every 5,000 crimps or monthly will significantly enhance the tool life
and ensure a stable calibration. See Figure 7A or 7B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams for Crimp Hand Tools Only
(See Figure 11)
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 rotating the small slotted screw marked with an arrow. See Figure 11.
Warranty
This hand tool is for electrical terminal crimping purposes only. This hand 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.
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 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 when operating or maintaining this tool.
4. Use only the Molex terminals specified for crimping with this tool.
CAUTION: Repetitive use of this tool should be avoided.
Certification
Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools or determine tool life:
When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out
of service and replaced.
The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 7 of 8
Revision: E Revision Date: 06-30-23
APPLICATIONS FOR THE Power CRIMP Head
The chart below shows all applications for this Power Crimp Head:
Tool Order No.
Tool Description
Crimp Head
Order No.
Crimp Head
Description
Figure No.
63819-5500
Hand Crimp Tool
---
---
8
63816-0270
Battery Power Tool (110 V)
63816-1915
Power Crimp Head
9
63816-0280
Battery Power Tool (220 V)
63816-1915
Power Crimp Head
9
63816-1900
Electric Crimp Machine
63816-1915
Power Crimp Head
10
Crimp Tooling Applications
Hand Crimp Tool
Battery Powered Tool
Electric Crimp Machine
Figure 8
Figure 9
Figure 10
WARNING: NEVER operate, service or install tool kits or adjust the power crimp head without proper instruction
and without first reading and understanding the instructions in the proper manual or specification sheet. See chart
above for the correct manual or specification sheet.
WARNING: NEVER install tooling or service this tool while it is connected to any power source. Make sure the
power is turned off.
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.
HAND CRIMP
FRAME
TOOL KIT
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOL KIT
ELECTRIC CRIMP
MACHINE
POWER CRIMP
HEAD
LOCATOR
LOCATOR

Tool Kit for 9.14mm (.360") Pitch Crimp Terminal.
Doc No: ATS-6381955HM Release Date: 11-05-08 UNCONTROLLED COPY Page 8 of 8
Revision: E Revision Date: 06-30-23
RATCHET
RELEASE SCREW
Figure 11
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63819-5500
Hand Crimp Tool
Figure 11
1
---
Hand Crimp Frame
1
2
---
Tool Kit
1
3
63811-4773
Locator Base
1
4
63819-5575
Locator
1
Application Tooling Support
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.