molex 63819-3500 User manual

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 1 of 6
Revision: D Revision Date: 06-30-23
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL
Order Number
63819-3500
Application Tooling
Specification Sheet
FEATURES
A full cycle ratcheting hand tool ensures complete crimps.
Ergonomically designed soft handles for comfortable crimping.
Right- and left-handed applications.
Precisely designed crimping profiles with simple contact positioning.
Easy handling due to outstanding force ratio.
A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position.
Tooling can be installed in the 63816-1950 Power Crimp Adapter, which is installed into the 63816-0270 (110 V)
or 63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine.
This tool is RoHS compliant; however, RoHS compliance is not required.
SCOPE
Products: CP 2.8 receptacle for 1.0mm2type ID and IR wire with 2.80mm (.110"), CMC Wire Seal Receptacle,
Red.
Terminal Series No.
Terminal Order No.
Wire Size and Type
Insulation Diameter
Strip Length
Available in Reel only
AWG
mm²
mm
In.
mm
In.
98910
98910-1049
98910-1149
-
1.0 Type
ID and IR
1.75-2.15
.069-.085
4.90-5.10
.193-.201
98910-2049
98910-2149
64324
64324-1049
64324-1149
64324-2049
64324-2149
Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4A

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 2 of 6
Revision: D Revision Date: 06-30-23
CRIMP SPECIFICATION
Terminal Series No.
Bell Mouth
Bend up Bend down
Twist Roll
Conductor Brush
mm
In.
Degree
Degree
mm
In.
98910
0.1-0.5
.004-.020
2
2
2
3
0.2 - 0.6
.008-.024
64324
0.1-0.5
.004-.020
2
2
2
3
0.2 - 0.6
.008-.024
Seam: Seam shall not be open, and no wire allowed out of the crimping area.
After crimping, the conductor profiles should measure the following (See notes below).
Terminal
Series No.
Wire Size
Conductor
Insulation
Pull Force
Minimum
Crimp Height
(Ref)
Crimp Width
(Ref)
Crimp Height
(Ref)
Crimp Width
(Ref)
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb
98910
-
1,0
1.25-1.35
.049-.053
2.07
.081
4.60-4.80
.181-.189
5.00
.197
115
25.8
64324
-
1,0
1.25-1.35
.049-.053
2.07
.081
4.60-4.80
.181-.189
5.00
.197
115
25.8
TOOL QUALIFICATION NOTES
1. (Ref) means that the dimension provided is approximate because of the wide range of wires, conductor
stranding, insulation diameter and insulation hardness.
2. An occasional conductor crimp height measurement should be performed, and it should be used as the final
criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification.
Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force
specification. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip
the wire long enough so the terminal insulation grips do not contact the wire insulation.
NOTES:
1. This tool should only be used for the terminals and wire gauges specified on this document.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for the conductor sizes specified on this document. It may not give good insulation crimp
support for insulation sizes outside of the specified range.
4. Molex does not repair hand tools. See warranty on page 4. The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling become damaged or worn, a new tool must be purchased.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects - damage
can occur to the tool or die.

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 3 of 6
Revision: D Revision Date: 06-30-23
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. Lift up the wire stop blade.
2. Insert the terminal fully into the correct profile until the terminal
is fully seated and stops.
3. Bring down the wire stop blade.
4. Slide the pre-stripped wire with the seal into the wire stop
blade. See Figure 1.
5. Be sure to hold the wire in place until the terminal is fully crimped. See Figure 2.
6. Close the tool until the ratchet releases. The tool handles will then spring open.
7. Lift up the wire stop blade if it is still in down position.
8. Carefully remove the crimped terminal.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Note: To maintain a good brush control and a consistent bell mouth the crimping instructions must be followed.
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 weights 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.
Figure 2
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
SEAL
TERMINAL
PRE-STRIPPED
WIRE WITH SEAL
Figure 1
WIRE STOP
BLADE

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 4 of 6
Revision: D Revision Date: 06-30-23
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 lifting the ratchet release lever. See Figure 6.
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: Repetitive use of this tool should be avoided.
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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
CERTIFICATION
Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools or determine tool life:
When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out
of service and replaced.
The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 5 of 6
Revision: D Revision Date: 06-30-23
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
APPLICATIONS FOR THE MODULAR CRIMP HEAD
WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper Manual or Specification Sheet.
See Chart below for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging or turn off the Actuator from its power source.
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.
The chart below shows all applications for this Modular Crimp Head.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63819-3500
Hand Crimp Tool
---
---
3
63816-0270
Battery Power Tool (110 V)
63816-1950
Battery Power Crimp Adapter
4
63816-0280
Battery Power Tool (220 V)
63816-1950
Battery Power Crimp Adapter
4
63816-1900
Electric Crimp Machine
63816-1950
Battery Power Crimp Adapter
5
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
Electric Crimp Machine
Figure 3
Figure 4
Figure 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME
ELECTRIC
CRIMP
MACHINE
INSTALL BATTERY
POWERED ADAPTER WITH
CRIMP HEAD HERE

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-6381935HM Release Date: 07-25-08 UNCONTROLLED COPY Page 6 of 6
Revision: D Revision Date: 06-30-23
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
M4 X 14mm
LONG BHCS
2
5
1
M4 FLAT
WASHER
PARTS LIST
Hand Crimp Tool 63819-3500
Item
Order Number
Description
Quantity
REF
63819-3500
Hand Crimp Tool
Figure 6
1
---
Hand Crimp Frame
1
2
---
Modular Crimp Head
1
3
63819-3575
Locator
1
4
63816-0001
Locking Pin
2
5
63600-0525
Handle Spring
1
6
63600-0520
Crimping Spring
2
Application Tooling Support
E-Mail: [email protected]m
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective
owners.