molex 63819-4100 User manual

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal
Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 1 of 4
Revision: A Revision Date: 01-05-09
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
SEAM
HAND CRIMP TOOL
Specification Sheet
Or er No. 63819-4100
FEATURES
% A full cycle ratcheting hand tool ensures complete crimps
% Ergonomically designed soft handles
% Precisely designed crimping profiles with simple contact positioning
% Easy handling due to outstanding force ratio
% A-620 Class 2 compliant
% RoHS compliant although not required
SCOPE
Products: CTX 1.50mm Receptacle Crimp Terminal for 1.25, 1.50, and 2.00mm2 wires.
Terminal Or er No. Wire Size Insulation Diameter Wire Strip Length Terminal
Series Reel Form only Wire Style mm2 / AWG mm In. mm In.
AVSS 1.25
ISO 1.50
AVSS 2.00
502307
502307-0113
502307-1113
502307-2113
502307-0123
502307-1123
502307-2123 ISO 2.00
2.10-2. 0 .0 3-.110 4.50-5.00 .177-.197
Customer to cut off terminal from reel: 0.30mm (.012”) 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 4A

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal
Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 2 of 4
Revision: A Revision Date: 01-05-09
CONDITIONS:
Bell mouth Con uctor Brush Ben up Ben Down Twist Roll
Terminal
Series mm In. mm In. Degree Degree
502307 0.20-0.55 .00 -.022 0.20-0.70 .00 -.02 1.5 1.5 4 6
After crimping, the crimp profiles should measure the following (See notes on page 4).
Con uctor Crimp Reference Profile
Wire Size Height Punch Wi th
1.25mm2 1.50mm2 2.0mm2
Terminal
Series No.
Wire Style mm2 / AWG mm In. mm In. A B C
AVSS 1.25 1.20-1.30 .047-.051 2.20 .0 7 X
ISO 1.50 1.30-1.40 .051-.055 2.20 .0 7 X
ISO 2.00 1.45-1.55 .057-.061 2.20 .0 7 X
502307
AVSS 2.00 1.50-1.60 .059-.063 2.20 .0 7 X


Insulation Crimp Reference
Wire Size Height Maximum
Wi th Maximum
Pull Force
Minimum
Terminal
Series No.
Wire Style mm2 / AWG mm In. mm In. N Lb.
AVSS 1.25 2.60 .102 2. 0 .110 1 0.0 40.5
ISO 1.50 2. 0 .110 2. 0 .110 155.0 34.9
ISO 2.00 2. 0 .110 2. 0 .110 245.0 55.1
502307
AVSS 2.00 2. 0 .110 2. 0 .110 245.0 55.1


 Insulation crimp should meet IPC/WHMA-A-620 Class 2 compliance.
Pull Force should be measured with no influence from the insulation crimp.
The above specifications are guidelines to an optimum crimp.
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 the wire stop blade up.
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 into the wire stop blade. See
Figure 1. Be sure to hold the wire in place until the terminal is fully crimped. See Figure 2.
5. Close the tool until the ratchet releases, the tool handles will then spring open.
6. Lift the wire stop blade up if it is still in down position.
7. Carefully remove the crimped terminal.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be
followed.
TERMINAL
PRE
-
STRIPPED
WIRE
LOCATOR
Figure 1
WIRE STOP
BLADE

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal
Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 3 of 4
Revision: A Revision Date: 01-05-09
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.
4. 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 (See Figure 3)
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 pushing the ratchet release lever.
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
ays. Should such a defect occur, we would exchange the tool free of charge. This 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.
Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable. Variations in tools, terminals, and wire stranding and insulation types may affect
crimp height.
3. This tool is intended only for the wire types specified. It may not give a good insulation crimp support for all
insulation sizes.
4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips on
the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping Handbook
63 00-0029 for additional information on crimping and crimp testing.
6. Molex does not certify crimp hand tools.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals, applicators and
tooling.
Figure 2
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
RETAINER
SPACER

Hand Crimp Tool for CTX 1.50mm Receptacle Crimp Terminal
Doc No: ATS-63 194100 Release Date: 01-05-09 UNCONTROLLED COPY Page 4 of 4
Revision: A Revision Date: 01-05-09
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
2
1
Figure3
M4 X 14mm
LONG BHCS
3
M4 FLAT
WASHER
PARTS LIST
Item Number Or er Number Description Quantity
1 63600-0520 Crimping Spring 2
2 63600-0525 Handle Spring 1
3 63 11-4175 Locator 1
Americas Hea quarters
Lisle, Illinois 60532 U.S.A.
1- 00-7 MOLEX
[email protected]
Far East North Hea quarters
Yamato, Kanagawa, Japan
1-462-65-2324
[email protected]
Far East South Hea quarters
Jurong, Singapore
65-6-26 -6 6
[email protected]
European Hea quarters
Munich, Germany
49- 9-413092-0
[email protected]
Corporate Hea quarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: [phone]
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