molex TPX50-50 User guide

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals
Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 09-03-20
Application Tooling Specification
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
Modular crimp head is removable and can be used in the Electric Crimp Machine (Order No.
63816-1500), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)
Can also be used in the Battery Powered Tool Order No. 63816-0270 (110 V) or 63816-0280
(220 V), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)
SCOPE
Products: TPX50-50 Large Grip Receptacle Crimp Terminals, 0.50mm² FLR91X-A XLPO Wire.
Terminal Series
No.
Terminal Order No.
Wire
Insulation Diameter
Strip Length (Ref)
Wire Type
Wire Size
mm
In.
mm
In.
201691
201691-4320
201691-4321
FLR91X-A XLPO
0.50mm2
1.40-1.60
.055-.063
3.50
.138
Order Number
213309-0500
Type 4A

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals
Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 09-03-20
DEFINITION OF TERMS
CRIMP SPECIFICATION
The following crimp specifications are based on AS document 2016910000 Rev. B3:
Feature
Requirement
1. Bend Up
1° Max
2. Bend Down
1° Max
3. Twist
2° Max
4. Roll
Not Applicable
5. Bell Mouth Rear
0.10-0.40mm (.004-.016”)
6. Bell Mouth Front
Not Applicable
7. Conductor Brush
0.30-0.70mm (.012-.028”)
8. Cut-Off Tab
0.20mm (.008”) Max, no burrs
Conductor Crimp
Wire Type
Wire Size
9. Crimp Height
10. Crimp Width (MAX)
FLR91X-A XLPO
0.50mm2
0.73-0.77mm
.029-.030 in.
1.45mm
.057 in.
Insulation Crimp
Wire Type
Wire Size
11. Crimp Height (MAX)
12. Crimp Width (MAX)
FLR91X-A XLPO
0.50mm2
1.85mm
.073 in.
1.50mm
.059 in.
Pull Force
Wire Type
Wire Size
Minimum Force
FLR91X-A XLPO
0.50mm2
75 N
16.8 lb.
To be measured with no influence
from the insulation crimp.
13. Conductor Anvil Flash
0.15mm (.006”) Max
14. Conductor Grip Step
0.01-0.21mm (.000-.008”)
15. Insulation Grip Step
0.00-0.20mm (.000-.008”) above datum D
16. Crimp Bulge
1.25mm (.049”) Max within crimp/transition area
Misc.
Wire Type
Wire Size
17. Wing Dissymmetry
18. Space Between Wing Tips
and Crimp Bottom
FLR91X-A XLPO
0.50mm2
0.00-0.10mm
.000-.004 in.
No contact
SECTION K-K
SECTION L-L
K
K
L
L
CRIMP/TRANSITION
7
D
D

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals
Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 09-03-20
Figure 3
WIRE
TERMINAL
LOCATOR
INSULATION
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR
ANVIL
CONDUCTOR
PUNCH
WIRE STOP BLADE
WIRE
INSULATION
PUNCH
Figure 2
TERMINAL
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. It must lie between
the minimum and maximum crimp height specification.
3. 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 sheet.
2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for metric conductor sizes. 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 5. 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.
5. Conductor crimp height should be used as the final criterion for an acceptable crimp. Refer to
Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
6. Molex does not certify hand crimp tools.
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.
1. With the hand tool in the open position, pivot the
terminal locator open by pulling up on the locator
knob, and lift the wire stop blade. See Figure 1.
2. Insert the terminal into the profile until the terminal is
fully seated and stops. Make sure the wire stop blade
is fully seated on the terminal behind the conductor
grip section.
3. Gently pivot the locator closed.
4. Bring down the wire stop blade.
TERMINAL
SEATED IN
LOCATOR
SWING
LOCATOR
OPEN
Figure 1
HAND TOOL
OPEN
WIRE
STOP
BLADE

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals
Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 09-03-20
INCORRECT
Figure 5
CORRECT
INCORRECT
M4 BHCS
PIVOT
LOCATOR
Figure 4
5. Slide the pre-stripped wire into the terminal, making sure to aim the wire brush toward
the tip point on the wire stop blade. See Figure 2. Align the wire so that it is parallel and
sitting into the terminal. Maintain a light and constant pressure on the wire that is
seated in the terminal at all times. (Do not let go of the wire.) Be sure to hold the wire
and terminal in place until the terminal is fully crimped. See Figure 3.
6. Close the tool until the ratchet releases.
7. Lift the wire stop blade.
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 good brush control and a consistent bell mouth, the crimping instructions must
be followed.
TERMINAL LOCATOR REPLACEMENT
This section describes the procedure for changing locators:
Removal
1. With the tool in the open position, pivot the terminal locator outward.
2. Remove the M4 BHCS. See Figure 4.
Installation
1. Place the locator on the hand tool. Install the M4 BHCS. See Figure 4.
2. Tighten the screw just enough to hold the locator. Make sure the locator can still float freely
with hand pressure.
3. Fully insert the proper terminal into the correct profile slot until the terminal is completely
seated and stops. Then, gently pivot the locator closed.
4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.
5. Gently pivot the locator open without disturbing the location.
6. Hold the locator firmly in place, and slowly tighten the M4 BHCS.

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals
Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 09-03-20
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 a 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 the hand tool, particularly from the crimping area. Oil transferred from
the crimping area onto certain terminations may affect the electrical characteristics of an
application.
5. When the 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 lifting the ratchet release lever. See Figure 9.
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, Molex 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 use 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.

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals
Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 09-03-20
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 plugged 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 servicing 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.
63816-0000
Hand Crimp Frame (Short)
—
—
6
63816-0050
Hand Crimp Frame (Long)
—
—
6
63816-0270
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
7
63816-0280
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
7
63816-1500
Electric Crimp Machine
63816-0600
Battery Power Crimp Adapter
8
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
Electric Crimp Machine
Figure 6
Figure 7
Figure 8
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT
MODULAR
CRIMP
HEAD
BATTERY
POWERED
CRIMP
ADAPTER
LOCKING
PINS
LOCKING
PINS
BATTERY
POWERED
TOOL
ELECTRIC
CRIMP
MACHINE
MODULAR
CRIMP HEAD
BATTERY
POWER CRIMP
ADAPTER

Hand Crimp Tool for TPX50-50 Large Grip Receptacle Crimp Terminals
Doc. No: 2133090500 Release Date: 09-03-20 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 09-03-20
PARTS LIST
Item
Order Number
Description
Quantity
1
63816-0000
Hand Crimp Frame (Short)
1
2
213309-0575
Locator
1
3
63816-0001
Locking Pin
2
4
63600-0525
Handle Spring
1
5
63600-0520
Crimping Spring
2
Application Tooling Support
Phone: (402) 458-TOOL (8665)
E-Mail: [email protected]
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.
1
4
3
5
2
HANDLE
SPRING
CRIMPING
SPRING (2)
Figure 9
RATCHET
RELEASE LEVER
LOCATOR
M4 X 8mm
LONG BHCS