molex 63819-2800 User manual

Hand Crimp Tool For 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminals
Doc No: ATS-638192800 R l as Dat : 07-08-08 UNCONTROLLED COPY Pag 1 of 7
R vision: B R vision Dat : 01-27-12
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP
TOOL
Application Tooling
Specification S eet Order No. 63819-2800
FEATURES
 A full cycl ratch ting hand tool nsur s compl t crimps
 Ergonomic soft grip handl s for comfortabl crimping
 A pr cision us r-fri ndly t rminal locator wir stop holds t rminals in th prop r crimping position
 Right and L ft hand d applications
 This tool is IPC/WHMA A-620 Class 2 compliant
 This tool is RoHS compliant, how v r RoHS compliant is not r quir d
SCOPE
Products: 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminal, 22-26 AWG.
Terminal Series No.
Terminal Order No. Wire Size Insulation Diameter Strip Lengt
Loose 

Reel AWG mm² mm In. mm In.
502438 502438-0100 502438-0000 22-26 0.34-0.13 0.90-1.50 .035-.059 1.90-2.30 .075-.091
Custom r to cut off t rminal from r l: 0.20mm (.008”) maximum Cut-off Tab.
DEFINITION OF TERMS
Th abov t rminal drawing is a g n ric t rminal r pr s ntation. It is not an imag of a t rminal list d in th
scop .
TYPE 4D

Hand Crimp Tool For 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminals
Doc No: ATS-638192800 R l as Dat : 07-08-08 UNCONTROLLED COPY Pag 2 of 7
R vision: B R vision Dat : 01-27-12
CONDITIONS:
Aft r crimping, th conductor profil s should m asur th following.
Terminal
Series No
Wire Size Conductor Crimp Insulation Crimp Pull Force
Minimum Profile
Heig t (Ref.) Widt (Ref.) Heig t (Ref.) Widt (Ref.)
AWG mm2 mm In. Mm In. mm In. mm In. N Lb. 22 24 26
502438
22 0.34 0.83-0.88 .033-.035 1.20 .047 1.75 .069 1.45 .057 35.6 8.00 X
24 0.20 0.75-0.80 .029-.031 1.20 .047 1.65 .065 1.45 .057 22.3 5.00 X
26 0.12 0.70-0.75 .028-.030 1.20 .047 1.55 .061 1.45 .057 13.4 3.00 X
• Tool Qualification Not s:
1. Pull Forc should b m asur d with no influ nc
from th insulation crimp.
2. Th abov sp cifications ar guid lin s to an
optimum crimp.
▲Insulation Crimp Note:
Du to th t rminal’s insulation grip d sign and/or
insulation diam t r rang , this tool us s “ov rlap” form
g om try in th insulation punch. This produc s an
ov rlap insulation crimp (A620 – compliant). Whil th
insulation punch profil may app ar “lopsid d”, this is
a normal condition for this tool. S figur to th right.
(Som tools with multipl crimp pock ts may not hav th “ov rlap” profil on all pock ts).
CAUTION: Install only Mol x t rminals list d abov with this tool. Do not crimp hard n d obj cts as damag can
occur to th tool or di .
Note:
A crimp h ight chart is provid d with this manual
as R f r nc Only. Du to th wid rang of
wir s, strands, insulation diam t rs, and
durom t rs availabl , actual crimp h ight
m asur m nts may v ry slightly. An occasional,
d structiv , pull forc t st should b p rform d to
ch ck hand tool crimp. Pull Forc valu Must
xc d th Minimum pull forc sp cifications
list d.
OPERATION
CAUTION: Install only Mol x t rminals list d abov with this tool. Do not crimp hard n d obj cts as damag can
occur to th tool or di .
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool For 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminals
Doc No: ATS-638192800 R l as Dat : 07-08-08 UNCONTROLLED COPY Pag 3 of 7
R vision: B R vision Dat : 01-27-12
RELEASE
LOCATOR
BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
Figure 5
TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
Op n th tool by squ zing th handl s tog th r. At th nd of th closing strok , th ratch t m chanism will
r l as th handl s and th hand tool will spring op n. S Figur 1.
Crimping Terminals
1. S l ct th d sir d t rminal list d in th pr c ding charts.
2. Mak sur th c nt r of th locator is in th down position. With th
locator attach d, push th locator button on th back of th hand tool to
bring th locator forward through th tooling. S Figur 2.
3. Whil holding th locator button in, load th t rminal into th prop r n st
op ning in th locator bas d on th wir gaug or t rminal typ
markings on th hand tooling. S Figur 3.
4. R l as th locator button, allowing th locator to r turn to th crimping
position.
5. Clos th tool handl until th first ratch t position ngag s. S Figur
4.
6. Ins rt th prop rly stripp d wir through th t rminal and against th
wir stop. S Figur 5.
7. Crimp th t rminal by squ zing th tool handl s until th ratch t
m chanism cycl has b n compl t d. R l as th handl s to op n
th jaws.
Not : Th tamp r proof ratch t action will not r l as th tool until it has b n fully clos d.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool For 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminals
Doc No: ATS-638192800 R l as Dat : 07-08-08 UNCONTROLLED COPY Pag 4 of 7
R vision: B R vision Dat : 01-27-12
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
8. R mov th crimp d t rminal from th t rminal
locator by pulling on th wir .
9. Visually insp ct th crimp d t rminal for prop r
crimp location.
10. On som larg O.D. wir s, it may not b
possibl to ins rt th wir with th tool partially
clos d. Thos wir s should b ins rt d with th
hand tool in th op n position. Ins rt th wir
abov th t rminal in th punch and against th
wir stop th n clos th tool. S Figur 6.
Locator Replacement
S th parts list on th last pag of this docum nt for th prop r locator ord r numb r. Follow th st ps b low to
r plac th locator.
1. Op n th crimp hand tool.
2. Squ z g ntly on th low r ar a shown in Figur 7A with your thumb and ind x fing r. Th low r tabs of th
locator should dis ngag from th hand tool.
3. Lift and pull away from th hand tool. Th top locator hooks should slip out of th top slots asily. S Figur
7A.
4. To r install th n w locator, mak sur th hand tool is in th op n position.
5. Pr ss th r d ins rt down as far as it will go as shown in Figur 7B.
6. Holding onto th low r part of th locator with your thumb and ind x fing r, ins rt th locators top hooks (2)
into th hand tool top slots.
7. Rotat th locator down and pr ss th low r tabs into th two bottom slots of th hand tool. To s cur th
locator into plac , th low r tabs must snap into plac on th hand tool fram .
TERMINAL
Figure 6
WIRE
WIRE STOP

Hand Crimp Tool For 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminals
Doc No: ATS-638192800 R l as Dat : 07-08-08 UNCONTROLLED COPY Pag 5 of 7
R vision: B R vision Dat : 01-27-12
MATCH
UP MARKS
FRONT
BACK
Figure 9
Rig t or Left Hand Operation
This hand tool has an add d f atur that can b
conv rt d from a right hand d application to a l ft hand d
application. It is n c ssary to r v rs th tooling if using
th l ft hand d application along with th locator. Follow
th st ps b low:
1. Th locator must b r mov d b for r v rsing th
tooling.
2. R mov th M3 BHCS which is holding th upp r tooling.
3. Flip th upp r tooling to th opposit sid and r plac th M3 BHCS. Mak sur th small markings on th
front and back of th hand tool fram match up and ar on th outsid of th hand tool fram . S Figur 8
and 9.
4. Do th sam thing with th low r tooling and tight n th M3 scr ws. B sur th small markings lin up.
5. R install th locator by following th Instructions in th locator r plac m nt s ction.
Maintenance
It is r comm nd d that ach op rator of th tool b mad awar of, and r sponsibl for, th following maint nanc
st ps:
1. R mov dust, moistur , and oth r contaminants with a cl an brush, or soft,
lint fr cloth.
2. Do not us any abrasiv mat rials that could damag th tool.
3. Mak c rtain all pins; pivot points and b aring surfac s ar prot ct d with a
thin coat of high quality machin oil. Do not oil xc ssiv ly. Th tool was
ngin r d for durability but lik any oth r quipm nt it n ds cl aning and
lubrication for a maximum s rvic lif of troubl fr crimping. Light oil
(such as 30 w ight automotiv oil) us d at th oil points, v ry 5,000 crimps
or 3 months, will significantly nhanc th tool lif .
4. Wip xc ss oil from hand tool, particularly from crimping ar a. Oil
transf rr d from th crimping ar a onto c rtain t rminations may aff ct th
l ctrical charact ristics of an application.
5. Wh n tool is not in us , k p th handl s clos d to pr v nt obj cts from
b coming lodg d in th crimping di s, and stor th tool in a cl an, dry ar a.
Miscrimps or Jams
Should this tool v r b com stuck or jamm d in a partially clos d position, Do
Not forc th handl s op n or clos d. Th tool will op n asily by pr ssing up
on th ratch t r l as l v r in th movabl handl . S Figur 11.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure11

Hand Crimp Tool For 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminals
Doc No: ATS-638192800 R l as Dat : 07-08-08 UNCONTROLLED COPY Pag 6 of 7
R vision: B R vision Dat : 01-27-12
Figure 12
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 pr s t to 25-45
LBS. pr load. It may b n c ssary ov r
th lif of th tool to adjust tool handl
pr load forc . List d b low ar th st ps
r quir d to adjust th crimping forc of th
hand tool to obtain prop r crimp
conditions:
1. Hold th hand tool in th palm of your
hand as shown in Figur 12. Using
th ind x fing r squ z th link
towards th top of th hand tool fram .
This will r l as th pr load adjustm nt wh l.
2. Rotat th s tting wh l count r-clockwis (CCW) to incr as handl forc . Th numb rs will display high r.
To d cr as handl forc rotat th s tting wh l clockwis (CW).
3. R l as th link to lock th s tting wh l in plac .
4. Ch ck th crimp sp cifications or conduct a pull t st aft r tool handl pr load forc is adjust d.
Warranty
This tool is for l ctrical t rminal crimping purpos s only. This tool is mad of th b st quality mat rials. All vital
compon nts ar long lif t st d. All tools ar warrant d to b fr of manufacturing d f cts for a p riod of 30
days. Should such a d f ct occur, w will r pair or xchang th tool fr of charg . This r pair or xchang will
not b applicabl to alt r d, misus d, or damag d tools. This tool is d sign d for hand us only. Any clamping,
fixturing, or us of handl xt nsions voids this warranty.
CAUTION: Mol x crimp sp cifications ar valid only wh n us d with Mol x t rminals and tooling.
CAUTIONS:
1. Manually pow r d hand tools ar int nd d for low volum or fi ld r pair. This tool is NOT int nd d for
production us . R p titiv us of this tool should b avoid d.
2. Insulat d rubb r handl s ar not prot ction against l ctrical shock.
3. W ar y prot ction at all tim s.
4. Us only th Mol x t rminals sp cifi d for crimping with this tool.
Certification
Mol x do s not c rtify or r -c rtify hand tools but rath r suppli s th following guid lin s for custom rs to r -c rtify
hand tools.
% This tool is qualifi d to pull forc only. S th Mol x w b sit for th Quality Crimp Handbook for mor
information on pull t sting.
% If th tool do s not m t minimum pull forc valu s, handl pr load should b incr as d and th pull t st
r run, (S How to Adjust Pr load).
% Wh n th hand tool is no long r capabl of achi ving minimum pull forc , it should b tak n out of s rvic and
r plac d.

Hand Crimp Tool For 2.00mm (.079”) Pitch CLIK-Mat ™ Wir -to-Board Crimp T rminals
Doc No: ATS-638192800 R l as Dat : 07-08-08 UNCONTROLLED COPY Pag 7 of 7
R vision: B R vision Dat : 01-27-12
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63819-2800 Hand Crimp Tool Figur 13
1 63819-2875 Locator Ass mbly 1
2 63810-0104 Spring, R turn 1
3 63810-0105 Spring, Ratch t 1
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