molex 63819-0600 User manual

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 1 of 9
Revision: D Revision Date: 09-17-10
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Application Tooling
Speci ication Sheet
Tool Kit
Order No. 63819-0670
Hand Crimp Tool
Order No. 63819-0600
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
 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
SCOPE
Products: 1.80mm (.070”) Wide VersaBlade™ Wire –to-Wire Crimp Terminal, 14-18 AWG.
Terminal Series No. Terminal Order No. Wire Size 


Insulation Diameter
Maximum Strip Length

Available in
R
eel orm only
AWG
mm²
mm
in
mm
in
35745
35745
-
0210
14
-
18
2.00
-
0.80
.150
3.80
4.00
-
4.80
.157
-
.189
35746
35746
-
0210
14
-
18
2.00
-
0.80
.150
3.80
4.00
-
4.80
.157
-
.189
35747
35747
-
0210
14
-
18
2.00
-
0.80
.150
3.80
4.00
-
4.80
.157
-
.189
35748
35748
-
0210
14
-
18
2.00
-
0.80
.150
3.80
4.00
-
4.80
.157
-
.189

The terminals above are reeled parts only. Customer to cut off term
inal from reel: 0.30mm (.012”) maximum.
See Conditions on Page 2.
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 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 2 of 9
Revision: D Revision Date: 09-17-10
▲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. (Some tools with
multiple crimp pockets may not have the
“overlap” profile on all pockets).
CONDITIONS:
After crimping, the conductor profiles should
measure the following (see notes below).
Terminal Series No. Wire Size
Conductor
Pull Force
Minimum Pro ile
Crimp Height (Re )
Punch
Width (Re )
AWG
mm
2
mm
I
n.
mm
I
n.
N
Lb.
A
B
C
35745
14
2.00
1.60
-
1.70
.063
-
.067
2.50
.098
147.1
33.1
X
16
1.30
1.50
-
1.60
.059
-
.063
2.50
.098
127.6
28.7
X
18
0.80
1.35
-
1.45
.053
-
.057
2.50
.098
97.8
22.0
X
35746
14
2.00
1.60
-
1.70
.063
-
.067
2.50
.098
147.1
33.1
X
16
1.30
1.50
-
1.60
.059
-
.063
2.50
.098
127.6
28.7
X
18
0.80
1.35
-
1.45
.053
-
.057
2.50
.098
97.8
22
.0
X
35747
14
2.00
1.60
-
1.70
.063
-
.067
2.50
.098
147.1
33.1
X
16
1.30
1.50
-
1.60
.059
-
.063
2.50
.098
127.6
28.7
X
18
0.80
1.35
-
1.45
.053
-
.057
2.50
.098
97.8
22.0
X
35748
14
2.00
1.60
-
1.70
.063
-
.067
2.50
.098
147.1
33.1
X
16
1.30
1.50
-
1.60
.059
-
.063
2.50
.098
127.6
28.7
X
18
0.80
1.35
-
1.45
.053
-
.057
2.50
.098
97.8
22.0
X



To Achieve IPC
-
A
-
620 Class 2 Crimps, the ollowing over
-
all wire insulation diameter ranges are recommended:
1. Profile A: 2.30-3.20mm (.091-.126 inch)
2. Profile B: 2.80-3.60mm (.110-.142 inch)
3. Profile C: 2.00-2.80mm (.079-.110 inch)
Tool Qualification otes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
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, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the
minimum pull force specifications listed.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 3 of 9
Revision: D Revision Date: 09-17-10
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
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL
IN PLACE
Figure 3
LOCATOR LATCH
IN OPEN POSITION
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.
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 the
top of the brass pivot
shaft.

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 4 of 9
Revision: D Revision Date: 09-17-10
Figure 5
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCK
LATCH IN
UP RIGHT
POSITION
LOCATOR
CLOSED
Figure 4
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
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.
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, it will correspond with
the 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.
Figure 6
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 5 of 9
Revision: D Revision Date: 09-17-10
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 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 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 or Crimp Hand Tools Only
(See Figure 10
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 10.
Warranty
This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit 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.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A
Figure 7B

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 6 of 9
Revision: D Revision Date: 09-17-10
CAUTIONS
1. Manually powered hand tools are intended for low volume or field repair. This tool is OT 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: Repetitive use of this tool should be avoided.
Certi ication
Molex does not certify or re-certify commercial grade 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.
% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.
% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 7 of 9
Revision: D Revision Date: 09-17-10
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Order no.
Tool
Description
Power
Head
Order No.
Adapter
Description
Figure
No.
63819-0670
6381
0
-
1050
Hand Crimp Frame (Short)
/A
/A
8
6381
0
-
100
0
Hand Crimp Frame (Long)
/A
/A
8
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp Head
9
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp Head
9
Applications or the Tool Kit
Hand Crimp Tool
Battery Powered T
ool
Figure
8
Figure
9
WARNING: NEVER operate service, 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 into 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 serving this tool.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 8 of 9
Revision: D Revision Date: 09-17-10
RATCHET
RELEASE SCREW
Figure 10
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
1
63810
-
1000
Hand Crimp Frame (Long)
1
2
63819
-
06
70
Tool Kit with
Locator
1
3
6381
9
-
06
7
3
Locator Base
1
4
63819
-
06
75
Locator (only)
R
EF

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381906HM Release Date: 08-29-07 UNCONTROLLED COPY Page 9 of 9
Revision: D Revision Date: 09-17-10
Figure 11
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63819-0670 63819-0670 Tool Kit 1
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