molex 63819-4400 User manual

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals
Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 10-31-08
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
Specification Sheet
Or er No. 63819-4400
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
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal, 26-28 AWG.
1.25mm (.049") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal, 26-28 AWG.
Insulation Diameter
Terminal Or er No. Wire Size IPC/WHMA-A620 Terminal Strip Length
Terminal
Series No.
Loose Piece 

Reel AWG mm² mm In. mm In. mm In.
501930-0200 501930-0100
501930 501930-1200
501930-1100
26-28 .136-.079 0.80-1.00 .032-.039 0.80-1.00 .031-.039 1.50-1.70 .059-.067
502381-0000
502381 502381-0010 26-28 .136-.079 0.80-1.00 .032-.039 0.80-1.00 .031-.039 1.50-1.70 .059-.067
Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.
To achieve optimum IPC-A620 Class 2 insulation crimps, use this insulation OD range.
Overall insulation OD specification for terminal.
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 1.25mm (.049") Pitch Crimp Terminals
Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 10-31-08
CONDITIONS:
After crimping, the conductor profile should measure the following.
Con uctor Profile
Wire Size Crimp Height Crimp Wi th (Ref)
501930 502381
Terminal Series No.
AWG mm2 mm In. mm In. 26 28 26 28
26 0.13 0.56-0.61 .022-.024 0.80 .031 X
501930 28 0.08 0.53-0.58
.021-.023 0.80 .031 X
26 0.13 0.56-0.61 .022-.024 0.80 .031 X
502381 28 0.08 0.53-0.58
.021-.023 0.80 .031 X
Insulation (Ref)
Wire Size Crimp Height Crimp Wi th Pull Force Minimum
Terminal Series No.
AWG mm2 mm In. mm In. N Lb.
26 0.13 1.19-1.25 .047-.049 0.80 .031 9.8 2.20
501930 28 0.08 1.15-1.21
.045-.048 0.80 .031 9.8 2.20
26 0.13 1.18-1.28 .046-.050 0.80 .031 9.8 2.20
502381 28 0.08 1.15-1.25
.045-.049 0.80 .031 9.8 2.20
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.
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.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals
Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 10-31-08
RELEASE
LOCATOR BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
WIRE TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE STOP IS PART OF
THE LOCATOR
Figure 5
PRE
-
STRIPPED
WIRE
TERMINAL
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.
ote: 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.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATC
HET
POSITION
OPEN
POSITION

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals
Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 10-31-08
Figure
8
PUSH ON
HANDLE
AWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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.
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 7B.
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.
T
ERMINAL
Figure 6
WIRE
WIRE STOP
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SUR
E
CENTER OF LOCATORR
IS IN THE
DOWN POSITION
Figure 7B

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals
Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 10-31-08
Right or Left Han 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.
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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure
10
RATCHET RELEASE
LEVER
Figure
11
MATCH
UP MARKS
FRONT
BACK
Figure
9

Hand Crimp Tool For 1.25mm (.049") Pitch Crimp Terminals
Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 10-31-08
Figure 1
2
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
How to A just Tool Preloa (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 10. 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.
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 OT 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 1.25mm (.049") Pitch Crimp Terminals
Doc o: ATS-638194400 Release Date: 10-31-08 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 10-31-08
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Or er Number Description Quantity
REF 63819-4400 Hand Crimp Tool Figure 13
1 63819-4475 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
Americas Hea quarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
[email protected]
Far East North Hea quarters
Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
Far East South Hea quarters
Jurong, Singapore
65-6-268-6868
[email protected]
European Hea quarters
Munich, Germany
49-89-413092-0
[email protected]
Corporate Hea quarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: [phone]
Visit our Web site at http://www.molex.com