molex 63819-9200 User manual

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 1 of 9
Revision: B Revision Date: 05-07-10
HAND CRIMP TOOL
Specification Sheet
Order No. 6 819-9200
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: MX150 Cable Seal Blade and Receptacle Crimp Terminals, 0.75-1.00mm2 metric and 1 -20 AWG
Wire Size and Type 

Insulation Diameter Strip Length Terminal
Series No.
Terminal Order No. AWG mm² mm In. mm In.
TXL-1 --- 1.91-2.06 .075-.0 1
TXL-20 --- 1.70-1. 5 .067-.073
--- ISO 1.00 1.90-2.10 .075-.0 3
340 0 340 0-1002 340 0-1104 340 0-1204
--- ISO 0.75 1.70-1.90 .067-.075
TXL-1 --- 1.91-2.06 .075-.0 1
TXL-20 --- 1.70-1. 5 .067-.073
--- ISO 1.00 1.90-2.10 .075-.0 3
340 1 340 1-3004 340 1-5002
--- ISO 0.75 1.70-1.90 .067-.075
TXL-1 --- 1.91-2.06 .075-.0 1
TXL-20 --- 1.70-1. 5 .067-.073
--- ISO 1.00 1.90-2.10 .075-.0 3
340 3 340 3-3002
--- ISO 0.75 1.70-1.90 .067-.075
5.15 .203


 See crimp specification for the individual Insulation Diameter.
Terminals were validated per USCAR-21 using the following wire specifications:
M1L-123A (TXL), and M1L-126A1(metric)
TYPE 4D

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 2 of 9
Revision: B Revision Date: 05-07-10
CONDUCTOR BRUSH
STRIP LENGTH
SEAM
INSULATION CRIMP
CUT-OFF
TAB
BELL MOUTH
TWISTING
ROLLING
BEND DOWN
WIRE
SEAL
TERMINAL WIDTH NOT TO EXCEED
2.65mm AFTER CRIMPING
BEND UP
THIS AREA
C
ONDUCTOR
CRIMP
CONDUCTOR BRUSH
STRIP LENGTH
SEAM
INSULATION CRIMP
CUT-OFF
TAB
BELL MOUTH
TWISTING
ROLLING
BEND DOWN
WIRE
SEAL
TERMINAL WIDTH NOT TO EXCEED
2.62mm AFTER CRIMPING
BEND UP
THIS AREA
CONDUCTOR CRIMP
DEFINITION OF TERMS (Blade)
DEFINITION OF TERMS (Receptacle)
CRIMP SPECIFICATION
Bell mouth 

Conductor Brush Maximum
Terminal
Series No.
mm In. mm In.
340 0
340 1
340 3
0.30-0.70 .012-.02 0.40 .016
Not to exceed above the conductor crimp height

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 3 of 9
Revision: B Revision Date: 05-07-10
WIRE
INSULATION SEAL
0.70mm (REF)
SEAL POSTION
Bend up Bend down Twist Roll
Terminal
Series No.
Degree Degree
340 0
340 1
340 3
3 3 3 3
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
After crimping, the crimp profiles should measure the following:
Conductor
Wire Size and Type
Crimp Height Crimp Width Pull Force Minimum
Terminal Series No.
AWG mm² mm In. mm In. N Lb.
TXL-1 --- 1.20-1.30 .047-.051 2.05-2.25 .0 1-.0 9 90 20.2
TXL-20 --- 1.10-1.20 .043-.047 2.05-2.25 .0 1-.0 9 75 16.9
--- ISO 1.00 1.25-1.35 .049-.053 2.05-2.25 .0 1-.0 9 120 27.0
340 0
--- ISO 0.75 1.20-1.30 .047-.051 2.05-2.25 .0 1-.0 9 90 20.2
TXL-1 --- 1.20-1.30 .047-.051 2.05-2.25 .0 1-.0 9 90 20.2
TXL-20 --- 1.10-1.20 .043-.047 2.05-2.25 .0 1-.0 9 75 16.9
--- ISO 1.00 1.25-1.35 .049-.053 2.05-2.25 .0 1-.0 9 120 27.0
340 1
--- ISO 0.75 1.20-1.30 .047-.051 2.05-2.25 .0 1-.0 9 90 20.2
TXL-1 --- 1.20-1.30 .047-.051 2.05-2.25 .0 1-.0 9 90 20.2
TXL-20 --- 1.10-1.20 .043-.047 2.05-2.25 .0 1-.0 9 75 16.9
--- ISO 1.00 1.25-1.35 .049-.053 2.05-2.25 .0 1-.0 9 120 27.0
340 3
--- ISO 0.75 1.20-1.30 .047-.051 2.05-2.25 .0 1-.0 9 90 20.2
Insulation
Wire Size and Type 

Insulation Diameter
Crimp Height Crimp Width
Terminal Series No.
AWG mm² mm In. mm In. mm In.
TXL-1 --- 1.91-2.06 .075-.0 1 3.60-3. 0 .142-.150 3.45-3.65 .136-.144
TXL-20 ---- 1.70-1. 5 .067-.073 3.50-3.70 .13 -.146 3.45-3.65 .136-.144
--- ISO 1.00 1.90-2.10 .075-.0 3 3.60-3. 0 .142-.150 3.45-3.65 .136-.144
340 0
--- ISO 0.75 1.70-1.90 .067-.075 3.50-3.70 .13 -.146 3.45-3.65 .136-.144
TXL-1 --- 1.91-2.06 .075-.0 1 3.60-3. 0 .142-.150 3.45-3.65 .136-.144
TXL-20 ---- 1.70-1. 5 .067-.073 3.50-3.70 .13 -.146 3.45-3.65 .136-.144
--- ISO 1.00 1.90-2.10 .075-.0 3 3.60-3. 0 .142-.150 3.45-3.65 .136-.144
340 1
--- ISO 0.75 1.70-1.90 .067-.075 3.50-3.70 .13 -.146 3.45-3.65 .136-.144
TXL-1 --- 1.91-2.06 .075-.0 1 3.60-3. 0 .142-.150 3.45-3.65 .136-.144
TXL-20 ---- 1.70-1. 5 .067-.073 3.50-3.70 .13 -.146 3.45-3.65 .136-.144
--- ISO 1.00 1.90-2.10 .075-.0 3 3.60-3. 0 .142-.150 3.45-3.65 .136-.144
340 3
--- ISO 0.75 1.70-1.90 .067-.075 3.50-3.70 .13 -.146 3.45-3.65 .136-.144


Cable Seal Position On a Wire
(Before crimping)

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 4 of 9
Revision: B Revision Date: 05-07-10
Wire Size and Type 

Cable Seal Profile
Terminal Series No.
AWG mm² Manufacturer and Part No. Color 18
0.75
1.00 20
TXL-1 --- QSR E-1644-00 Green X
--- ISO 0.75 QSR E-1644-00 Green X
--- ISO 1.00 QSR E-1644-00 Green X
340 0
TXL-20 --- QSR E-1644-00 Green X
TXL-1 --- QSR E-1644-00 Green X
--- ISO 0.75 QSR E-1644-00 Green X
--- ISO 1.00 QSR E-1644-00 Green X
340 1
TXL-20 --- QSR E-1644-00 Green X
TXL-1 --- QSR E-1644-00 Green X
--- ISO 0.75 QSR E-1644-00 Green X
--- ISO 1.00 QSR E-1644-00 Green X
340 3
TXL-20 --- QSR E-1644-00 Green 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.
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.
LOCATOR
IN DOWN
POSTION
PUSH ON
THE
LOCATOR
BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 5 of 9
Revision: B Revision Date: 05-07-10
Figure 4 TERMINAL
WIRE AGAINST
THE
WIRE STOP
WIRE AND SEAL
POSITION
WIRE STOP IS
PART OF THE
LOCATOR
WIRE AND SEAL
POSITIONED IN
LOWER PART OF
THE PUNCHES
TERMINAL
RELEASE LOCATOR
BUTTON
TERMINAL
Figure
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
4. Release the locator button, allowing the locator to return to the crimping position.
5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the
upper tooling, until the wire is against the wire stop. See Figure 4.
6. Seal position should be under and inside the punches, keep this position while crimping.
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.
. Remove the crimped terminal from the terminal locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper crimp location.
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.

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 6 of 9
Revision: B Revision Date: 05-07-10
Figure 6
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M BHCS
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 5A 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 5A.
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 5B.
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.
Right 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 6 and 7.
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.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 5B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 5A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
FRONT BACK
MATCH
UP MARKS
Figure 7

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 7 of 9
Revision: B Revision Date: 05-07-10
Figure 10
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. See Figure .
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 9.
How to Adjust Tool Preload
(See Figure 10)
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
RATCHET RELEASE
LEVER
Figure 9
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTHS
OR
5,000 CRIMPS)
Figure 8

Hand Crimp Tool For MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page of 9
Revision: B Revision Date: 05-07-10
(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 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 MX150 Cable Seal Crimp Terminals
Doc No: ATS-63 199200 Release Date: 11-16-09 UNCONTROLLED COPY Page 9 of 9
Revision: B Revision Date: 05-07-10
2
Figure 11
1
PARTS LIST
Item Number Order Number Description Quantity
REF 63 19-9200 Hand Crimp Tool Figure 11
1 63 19-9275 Locator Assembly 1
2 63 10-0104 Spring, Return 1
3 63 10-0105 Spring, Ratchet 1
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[email protected]
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Fax: [phone]
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