molex 63819-3200 User manual

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page 1 of
Revision: B Revision Date: 10-04-10
STRIP
LENGTH
INSULATION
CRIMP
SEAM
WIRE
CONDUCTOR
CRIMP
Application Tooling
Specification Sheet
Tool it
Order No. 63819-3270
Hand Crimp Tool
Order No. 63819-3200
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
 Tool kits are easily installed into the Hand Crimp Tool or the 63 16-0300 Power Crimp Head which is installed
into the 63 16-0200 (110 V) or the 63 16-0250 (220 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
SCOPE
Products: Quick Disconnect, Female, Flag, for 0.50 and 0. 0mm² (20 and 1 AWG) wires.
Terminal
Series No.
Terminal Order No. Wire Size Insulation Diameter Strip Length
Reel AWG mm² mm In. mm In.
94030 94030-5000
94030-5001
0.50
2.10-2.60 .0 3-.102 6.0-7.0 .236-.276
20 (0.52)
0. 0
1 (0. 2)
Customer to cut off terminal from reel. Cut tab flush with terminal on both ends.
DEFINITION OF TERMS
TYPE 2C

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page 2 of
Revision: B Revision Date: 10-04-10
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes below).
Terminal
Series No.
Wire Size Conductor Crimp Profile
Height (Ref.) Width (Ref.)
AWG mm2 mm In. mm In. A B
94030
0.50 1.40 - 1.50 .055 - .059 2.35 .093 X
20 (0.52) 1.40 - 1.50 .055 - .059 2.35 .093 X
0. 0 1.50 – 1.60 .059 - .063 2.35 .093 X
1 (0. 2) 1.50 – 1.60 .059 - .063 2.35 .093 X
Terminal
Series No.
Wire Size Insulation Crimp Pull Force
Minimum
Height (Ref.) Width (Ref.)
AWG mm2 mm In. mm In. N Lb.
94030
0.50 2. 0 – 2.90 .110 - .114 3.45 max .136 max 7 .45 17.6
20 (0.52) 2. 0 – 2.90 .110 - .114 3.45 max .136 max 7 .45 17.6
0. 0 2.90 – 3.00 .114 - .11 3.45 max .136 max 117.6 26.4
1 (0. 2) 2.90 – 3.00 .114 - .11 3.45 max .136 max 117.6 26.4
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
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, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the
minimum pull force specifications listed.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head
follow the steps below:
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the
nest. Install the M4 x 10 long BHCS and tighten
in place.
2. Insert the Punches into the top slots of the nest.
Install the M4 x 1 long BHCS and tighten in
place. See Figure 1.

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page 3 of
Revision: B Revision Date: 10-04-10
Figure 2
JAWS
OPEN
TERMINAL
NURLED FASTENER
UPPER
TOOLING
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. Select the desired terminal listed in the preceding charts.
2. Before attempting to crimp any terminals, make sure all the upper
tooling is correctly placed into the upper jaw. The desired nest
being used for the proper wire size should be in the forward
position, (The marking on the upper tooling “A” for 0. mm ² or “B”
for 0.5mm²). This is done by removing the knurled fastener that
holds the upper tooling in place and then rotating it 1 0° to the correct position. Then, re-installing the
fastener. See Figure 2.
3. Place the terminal into the nest profile, centered on the nest as shown, with the outer edges of the crimp grips
flush with each side of the crimp die and the opening in the terminal centered below the forward leg of the right
punch. See Figure 3.
4. Partially close the tool until the terminal is held in place and re-position the terminal as necessary.
5. From the left side of the tool, insert the pre-stripped wire into the terminal until the conductor is centered, front
to rear, in the crimp grips. See Figure 3.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
7. Remove the crimped terminal. Inspect for proper
crimp location, and check for insulation closure.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal
to the wire.
2. Remove the crimped terminal from the terminal
locator by pressing down on the wire stop and
gently pulling on the wire. The terminal locator can
be in either position.
3. Visually inspect the crimped terminal for proper
crimp location.
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.
Figure 3
Note: The Terminal should be centered in
crimp nests with the outer edges of the crimp
grips flush with the jaws on both sides.
WIRE
CONDUCTOR OF THE TERMINAL CENTERED
IN CRIMP GRIPS FRONT TO REAR
SEE NOTE
BELOW
SEE NOTE
BELOW

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page 4 of
Revision: B Revision Date: 10-04-10
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 fine piece of
equipment it needs cleaning and
lubrication for a maximum service life of
trouble free crimping. Use a 30 weight
automotive (light) oil used at the oil
points, every 5,000 crimps or 3 months,
shown in Figure 4A or 4B 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 the ratchet release lever. See Figure 5.
How to Adjust Tool Preload (See Figure 5)
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. Remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel.
2. Remove the locking screw with a 2mm hex wrench. The wrench set (63 10-0101), is not supplied. It is sold
separately from the hand tool.
3. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase
handle force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. 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
RATCHET
RELEASE LEVER
Figure 5
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOC ING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHEC POINT
25.4MM
SETTING WHEEL
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 4A
Figure 4B

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page 5 of
Revision: B Revision Date: 10-04-10
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 commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools.
% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. 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.

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page 6 of
Revision: B Revision Date: 10-04-10
The chart below shows all applications for this Tool Kit.
Tool it
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
Adapter
Description
Figure
No.
63 19-3270
63 10-0100 Hand Crimp Frame (Short) N/A N/A 6
63 10-0400 Hand Crimp Frame (Long) N/A N/A 6
63 16-0200 Battery Power Tool (110 V) 63 16-0300 Power Crimp Head 7
63 16-0250 Battery Power Tool (220 V) 63 16-0300 Power Crimp Head 7
Applications for the Tool it
Hand Crimp Tool Battery Powered Tool
Figure 6 Figure 7
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper Manual or
Specification Sheet. See Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the
power is turned off.
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.
POWER
CRIMP
HEAD
LOC ING PINS
BATTERY
POWERED
TOOL
TOOLING IT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING
IT

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page 7 of
Revision: B Revision Date: 10-04-10
RATCHET
RELEASE SCREW
Figure 8
1
3
M4 X 12mm
LONG BHCS
NURLED
FASTENER
3
4
2
HAND TOOL PARTS LIST
Item Number Order Number Description Quantity
1 63 10-0100 Hand Crimp Frame (Short) 1
2 63 10-0101 Wrench Set (Not included) 0
3 63 10-0103 Repair Kit (Not included) 0
4 63 19-3270 Tool Kit 1

Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Doc No: ATS-63 1932HM Release Date: 03-23-09 UNCONTROLLED COPY Page of
Revision: B Revision Date: 10-04-10
Figure 9
1
2
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
POWER HEAD PARTS LIST
Item Order No Engineering No. Description Quantity
1
63 16-0300 63 16-0300 Power Crimp Head 1
2
63 19-3270 63 19-3270 Tool Kit 1
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