molex 63819-1500 User manual

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal
Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 1 of 7
Revision: C Revision Date: 05-22-13
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
R
OLLING
CONDUCTOR
CRIMP
TWISTING
Hand Crimp
Tool
Application Toolin
Specification Sheet Order No. 63819-1500
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 IPC/WHMA A-620 Class 2 compliant as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal, 28-32 AWG.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diamet
er
Strip Len th
Loose Piece

Reel
AWG
mm²
mm
In.
mm
In.
501193
501193
-
0100
501193
-
0000
501193
-
3000
28-32 0.08-0.04 0.80-0.56 .031-.022 1.00-1.30 .039-.051
501193
-
2100
501193
-
0099
501193
-
3100
501193
-
2000
501334
501334
-
0100
501334
-
0000
501334
-
2000
28
-
3
2
0.08
-
0.04
0.80
-
0.56
.031
-
.022
1.00
-
1.30
.039
-
.051

Customer to cut off terminal from reel: 0.
1
0
mm (.00
4
”) maximum Cut
-
off Tab.
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 4D

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal
Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 2 of 7
Revision: C Revision Date: 05-22-13
RELEASE
LOCATOR BUTTON
TERMINAL Fi ure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum Profile
Hei ht (Ref.)
Width (Ref.)
Hei
ht (Ref.)
Width (Ref.)
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
2
8
30
-
32
501193
28
0.08
0.44
-
0.48
.0173
-
.01
9
0.70
.028
1.00
.039
0.70
.028
9.8
2.20
X
30
0.05
0.40
-
0.44
.0157
-
.0173
0.70
.028
0.95
.037
0.70
.028
4.9
1.10
X
32
0.04
0.39
-
0.43
.0153
-
.017
0.70
.028
0.90
.035
0.70
.028
3.4
0.76
X
501334
28
0.08
0.44
-
0.48
.0173
-
.01
9
0.70
.028
1.00
.039
0.70
.028
9.8
2.20
X
30
0.05
0.40
-
0.44
.0157
-
.0173
0.70
.028
0.95
.037
0.70
.028
4.9
1.10
X
32
0.04
0.39
-
0.43
.0153
-
.017
0.70
.028
0.90
.035
0.70
.028
3.4
0.76
X
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.
At the end of the closing stroke, the ratchet
mechanism will release the handles and the hand
tool will spring open. See Figure 1.
Crimpin 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.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Fi ure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Fi ure 1

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal
Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 3 of 7
Revision: C Revision Date: 05-22-13
PRE
-
STRIPPED
WIRE
TERMINAL
Fi ure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
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.
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.
TERMINAL
Fi ure 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Fi ure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal
Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 4 of 7
Revision: C Revision Date: 05-22-13
Fi ure
8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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 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 specifications listed.
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.
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 7 .
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.
Ri ht 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 HCS which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side and
replace the M3 HCS. 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.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Fi ure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Fi ure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal
Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 5 of 7
Revision: C Revision Date: 05-22-13
MATCH
UP MARKS
FRONT
BACK
Fi ure 9
4. Do the same thing with the lower tooling and tighten
the M3 screws. e 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 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 30 weight automotive oil) used at the
oil points, every 5,000 crimps or 3 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.
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 Fi ure 12)
This hand tool is factory preset to 25-45 L S. 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Fi ure 10
RATCHET RELEASE
LEVER
Fi ure 11

Hand Crimp Tool For 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal
Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 6 of 7
Revision: C Revision Date: 05-22-13
Fi ure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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).
3. 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 30 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.
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.
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 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 1.00mm (.039") Pitch Pico-Clasp™ Wire-to- oard Crimp Terminal
Doc No: ATS-638191500 Release Date: 03-25-08 UNCONTROLLED COPY Page 7 of 7
Revision: C Revision Date: 05-22-13
RATCHET
RELEASE LEVER
2
Fi ure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63819
-
1
500
Hand Crimp Tool
Figure 13
1
63819
-
1
575
Locator Assembly
1
2
63810
-
0104
Spring, Return
1
3
63810
-
0105
Spring, Ratchet
1
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