molex 63819-2900 User manual

Hand Crimp Tool For Low Force Micro-Fit 3.0™ Crimp Terminals
Doc No: ATS- 38192900 Release Date: 12-10-08 UNCONTROLLED COPY Page 1 of 7
Revision: B Revision Date: 09-22-10
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. 63819-2900
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- 20 Class 2 compliant
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: Low Force Micro-Fit 3.0™ Crimp Terminals, 20-30 AWG.
Terminal Series No.
Terminal Order No. Wire Size Insulation Diameter Strip Lengt


Reel AWG mm² mm In. mm In.
4 235
4 235-0001 4 235-0002
20-24 0.50-0.20 1.30-1.85 .051-.073
2.54-2.92 .100-.115
4 235-5001 4 235-5002
4 235-0003 4 235-0004
2 -30 0.13-0.05 1.12-1.27 .044-.050
4 235-5003 4 235-5004
Customer to cut off terminal from reel: 0.25mm (.010”) 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 Low Force Micro-Fit 3.0™ Crimp Terminals
Doc No: ATS- 38192900 Release Date: 12-10-08 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: 09-22-10
RELEASE
LOCATOR
BUTTON
TERMINAL Figure 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
Heig t (Ref.) Widt (Ref.) Heig t (Ref.) Widt (Ref.)
AWG mm2 mm In. mm In. mm In. mm In. N Lb. 22-24 20 26-30
4 235
20 0.50 0.7 -0.81 .030-.032 1.40 .055 1.90 .075 1.85 .073 57.9 13.00 X
22 0.35 0. -0.7 .02 -.030 1.15 .045 1. 5 .0 5 1. 0 .0 3 35. 8.00 X
24 0.20 0. -0.7 .02 -.030 1.15 .045 1. 5 .0 5 1. 0 .0 3 22.3 5.00 X
2 0.13 0.45-0.5 .018-.022 1.00 .039 1.35 .053 1.35 .053 13.4 3.00 X
28 0.08 0.45-0.5 .018-.022 1.00 .039 1.35 .053 1.35 .053 8.9 2.00 X
30 0.05 0.45-0.5 .018-.022 1.00 .039 1.35 .053 1.35 .053 .7 1.50 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.
Crimping 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.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2

Hand Crimp Tool For Low Force Micro-Fit 3.0™ Crimp Terminals
Doc No: ATS- 38192900 Release Date: 12-10-08 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: 09-22-10
Figure 5 TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
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.
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.
. 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 .
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.
TERMINAL
Figure 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool For Low Force Micro-Fit 3.0™ Crimp Terminals
Doc No: ATS- 38192900 Release Date: 12-10-08 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: 09-22-10
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT BACK
Figure 9
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 7B.
. 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.
Rig t 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 BHCS which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side and
replace the M3 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 M3 screws. Be sure the small markings line up.
5. Reinstall the locator by following the Instructions in
the locator replacement section.
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

Hand Crimp Tool For Low Force Micro-Fit 3.0™ Crimp Terminals
Doc No: ATS- 38192900 Release Date: 12-10-08 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: 09-22-10
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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
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).
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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11

Hand Crimp Tool For Low Force Micro-Fit 3.0™ Crimp Terminals
Doc No: ATS- 38192900 Release Date: 12-10-08 UNCONTROLLED COPY Page of 7
Revision: B Revision Date: 09-22-10
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. 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 Low Force Micro-Fit 3.0™ Crimp Terminals
Doc No: ATS- 38192900 Release Date: 12-10-08 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: 09-22-10
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 3819-2900 Hand Crimp Tool Figure 13
1 3819-2975 Locator Assembly 1
2 3810-0104 Spring, Return 1
3 3810-0105 Spring, Ratchet 1
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