molex 63819-1300 User manual

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
mm
In.
mm
In.
1560
02
-
06
-
210
02
-
06
-
6119
02
-
06
-
2101
02
-
06
-
6118
18-24 0.82-0.20 1.52- .05 .060-.120 2.41- .04 .095-.120
02
-
06
-
6102
04
-
01
-
0805
02
-
06
-
6100
9
-
00
-
0278
02
-
06
-
610
9
-
00
-
0 27
02
-
06
-
6101
9
-
00
-
0 28
02
-
06
-
6104
9
-
00
-
0 0
02
-
06
-
6105
9
-
00
-
0 29
02
-
06
-
6112
02
-
06
-
6116
1561
02
-
06
-
110
04
-
01
-
0808
02
-
06
-
1101
04
-
01
-
0806
18-24 0.82-0.20 1.52- .05 .060-.120 2.41- .04 .095-.120
02
-
06
-
5102
9
-
00
-
0 1
02
-
06
-
1118
9
-
00
-
0279
02
-
06
-
510
9
-
00
-
0 4
02
-
06
-
5100
9
-
00
-
0 2
02
-
06
-
5104
02
-
06
-
5101
9
-
00
-
0
02
-
06
-
5109
02
-
06
-
5108
1786
02
-
06
-
2202
02
-
06
-
6202
02
-
06
-
2201
02
-
06
-
6201
18
-
24
0.82
-
0.20
1.52
-
.05
.060
-
.120
2.41
-
.04
.095
-
.120
1787
02
-
06
-
1202
02
-
06
-
1201
02
-
06
-
5205
18-24 0.82-0.20 1.52- .05 .060-.120 2.41- .04 .095-.120
02
-
06
-
5201
5005
08
-
70
-
0042
08
-
70
-
1012
08
-
70
-
0001
08
-
70
-
1011
18
-
24
0.82
-
0.20
1. 0
-
.00
.051
-
.118
2. 0
-
2.95
.090
-
.116
5006
08
-
70
-
004
08
-
70
-
1014
08
-
70
-
0002
08
-
70
-
101
18
-
24
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
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
1560
18
0.82
0.87
-
0.97
.0 4
-
.0 8
1.66
.065
2.62
.10
2.47
.097
20
0.52
0.85
-
0.95
.0
-
.0 7
1.65
.065
2.60
.102
2.46
.096
22
0. 2
0.82
-
0.92
.0 2
-
.0 6
1.50
.059
2.20
.087
2.2
.088
24
0.20
0.77
-
0.87
.0 0
-
.0 4
1.50
.059
2.12
.08
2.20
.087
1561
18
0.82
0.87
-
0.97
.0 4
-
.0 8
1.66
.065
2.62
.10
2.47
.097
20
0.52
0.85
-
0.95
.0
-
.0 7
1.65
.065
2.60
.102
2.46
.096
22
0. 2
0.82
-
0.92
.0 2
-
.0 6
1.50
.059
2.20
.087
2.2
.088
24
0.20
0.77
-
0.87
.0 0
-
.0 4
1.50
.059
2.12
.08
2.20
.087
1786
18
0.82
0.87
-
0.97
.0 4
-
.0 8
1.66
.065
2.62
.10
2.47
.097
20
0.52
0.85
-
0.95
.0
-
.0 7
1.65
.065
2.60
.102
2.46
.096
22
0. 2
0.82
-
0.92
.0 2
-
.0 6
1.50
.059
2.20
.087
2.2
.088
24
0.20
0.77
-
0.87
.0 0
-
.0 4
1.50
.059
2.12
.08
2.20
.087
1787
18
0.82
0.87
-
0.97
.0 4
-
.0 8
1.66
.065
2.62
.10
2.47
.097
20
0.52
0.85
-
0.95
.0
-
.0 7
1.65
.065
2.60
.102
2.46
.096
22
0. 2
0.82
-
0.92
.0 2
-
.0 6
1.50
.059
2.20
.087
2.2
.088
24
0.20
0.77
-
0.87
.0 0
-
.0 4
1.50
.059
2.12
.08
2.20
.087
5005
18
0.82
0.94
-
1.04
.0 7
-
.041
1.68
.066
2.65
.104
2.54
1.00
20
0.52
0.91
-
1.01
.0 6
-
.040
1.67
.065
2.58
.102
2.48
.098
22
0. 2
0.86
-
0.96
.0 4
-
.0 8
1.5
.060
2.27
.089
2.29
.090
24
0.20
0.84
-
0.94
.0
-
.0 7
1.52
.059
2.20
.079
2.22
.087
5006
18
0.82
0.94
-
1.04
.0 7
-
.041
1.68
.066
2.65
.104
2.54
1.00
20
0.52
0.91
-
1.01
.0 6
-
.040
1.67
.065
2.58
.102
2.48
.098
22
0. 2
0.86
-
0.96
.0 4
-
.0 8
1.5
.060
2.27
.089
2.29
.090
24
0.20
0.84
-
0.94
.0
-
.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
mm
2
N
Lb.
18
-
20
22
-
24
1560
18
0.82
89
-
0
20.00
X
20
0.52
66.8
15.00
X
22
0. 2
44.5
10.00
X
24
0.20
5.6
8.00
X
1561
18
0.82
89
-
0
20.00
X
20
0.52
66.8
15.00
X
22
0. 2
44.5
10.00
X
24
0.20
5.6
8.00
X
1786
18
0.82
89
-
0
20.00
X
20
0.52
66.8
15.00
X
22
0. 2
44.5
10.00
X
24
0.20
5.6
8.00
X
1787
18
0.82
89
-
0
20.00
X
20
0.52
66.8
15.00
X
22
0. 2
44.5
10.00
X
24
0.20
5.6
8.00
X
5005
18
0.82
98.0
22.00
X
20
0.52
66.8
15.00
X
22
0. 2
5 .4
12.00
X
24
0.20
5.6
8.00
X
5006
18
0.82
98.0
22.00
X
20
0.52
66.8
15.00
X
22
0. 2
5 .4
12.00
X
24
0.20
5.6
8.00
X
 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
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
11
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
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
6 819
-
1
00
Hand Crimp Tool
Figure 1
1
6 819
-
1
75
Locator Assembly (Red)
1
2
6 810
-
0104
Spring, Return
1
6 810
-
0105
Spring, Ratchet
1
http://www.molex.com