molex 63819-7300 User manual

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 1 of 9
Revision: B Revision Date: 10-11-10
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
TERMINAL
STRIP
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
SEAM
BELL MOUTH
WIRE
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63819-7370
Hand Crimp Tool
Ord r No. 63819-7300
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 and Crimp Tool or the 63816-0300 Power Crimp ead which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/W MA-A-620 Class 2 and Ro S compliant.
SCOPE
Products: 6.35mm (.250") Tab Slip-On Wire-to-Wire Receptacle Terminal, 14 -18 AWG.
T rminal Ord r No. Wir Siz Insulation Diam t r Strip L ngth
AWG mm In. mm In.
35725-5110 14 - 18 3.60 maximum .142 4.40 – 4.80 .173 - .189
Customer to cut off terminal from reel: 0.50mm (.019”) 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 2C

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 2 of 9
Revision: B Revision Date: 10-11-10
ANVILS
POWER
CRIMP
HEAD
Figur 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figur 2
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes below).
T rminal S ri s No.
Wir Siz Conductor Crimp Profil
H ight (R f.) Width (R f.)
AWG mm2 mm In. mm In. A B C
35725
14 2.08 1.65 – 1.75 .065 - .068 2.7 – 2.9 .106 - .114 X
16 1.30 1.45 – 1.55 .065 - .068 2.7 – 2.9 .106 - .114 X
18 0.82 1.30 – 1.40 .065 - .068 2.7 – 2.9 .106 - .114 X
T rminal S ri s No.
Wir Siz Insulation Crimp Pull Forc Minimum
H ight (R f.) Width (R f.)
AWG mm2 mm In. mm In. N Lb.
35725
14 2.08 --- --- 3.9 – 4.1 .154 - 161 274.4 61.6
16 1.30 --- --- 3.9 – 4.1 .154 - 161 196.0 44.0
18 0.82 --- --- 3.9 – 4.1 .154 - 161 147.0 33.0
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.
Not :
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 ead follow the steps below:

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 3 of 9
Revision: B Revision Date: 10-11-10
Anvils and Punch s Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long B CS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long B CS and tighten in place. See
Figure 1.
Locator Installation and R moval
Follow the steps below to install or replace the locator. See Figure 2.
To install th locator
1. Position the locator with the hole over the brass pivot shaft and snap it
into place.
To r mov th locator
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the
top of the brass pivot shaft.
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. Swing the terminal locator away from the crimp tool shown in Figure
2. Some terminals with large insulation grips may interfere with the
crimp tooling when swinging the locator into position. The terminal
must then be loaded into the locator in the closed/crimp position.
3. When using the locator, press down on the wire stop on the locator as
shown in Figure 2. Insert the proper terminal into the proper nest
opening. Make sure when choosing the nest opening, it will
Figur 3
LOCATOR
JAWS OPEN
TERMINAL
PUSH HERE
TO OPEN
WIRE STOP
SWING OPEN
LOCATOR
LOCATOR TERMINAL
IN PLACE
Figur 4
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE AGAINST
STOP Figur 5
WIRE STOP
WIRE

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 4 of 9
Revision: B Revision Date: 10-11-10
correspond with the A, B, or C profile on the hand tool.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Some large O.D. wires may need to be placed into the terminal before
closing the tool. Gently touch the wire stop with the end of the wire. 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 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.
8. Visually inspect the crimped terminal for proper crimp location.
For th Batt ry Pow r 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.
Locator R plac m nt
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. Swing the existing locator open and away from the
hand tool.
3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the
top of the brass pivot shaft. See Figure 6.
4. Replace it with the proper locator by putting
over the brass pivot shaft and snapping it into
place.
Maint nanc
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.
Figur 7B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 7A
SWING
LOCATOR
OPEN
PRESS DOWN ON
BRASS PIVOT SHAFT
LIFT UP LOCATOR
JAWS OPEN
Figur 6

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 5 of 9
Revision: B Revision Date: 10-11-10
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 7A or 7B 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 8.
How to Adjust Tool Pr load (S Figur 8)
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 (63810-0101), 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
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.
RATCHET
RELEASE LEVER
Figur 8
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 6 of 9
Revision: B Revision Date: 10-11-10
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.
C rtification
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 andbook 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 ow 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 Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 7 of 9
Revision: B Revision Date: 10-11-10
The chart below shows all applications for this Tool Kit.
Tool Kit
Ord r No.
Tool
Ord r no.
Tool
D scription
Pow r H ad
Ord r No.
Adapt r
D scription
Figur
No.
63819-7370
63810-0100 and Crimp Frame (Short) N/A N/A 9
63810-0400 and Crimp Frame (Long) N/A N/A 9
63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp ead 10
63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp ead 10
Applications for th Tool Kit
Hand Crimp Tool Batt ry Pow r d Tool
Figur 9 Figur 10
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp ead 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
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING
KIT

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 8 of 9
Revision: B Revision Date: 10-11-10
RATCHET
RELEASE SCREW
Figur 11
1
6
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
5
3
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
HAND TOOL PARTS LIST
It m Numb r Ord r Numb r D scription Quantity
1 63810-0400 and Crimp Frame (Long) 1
2 63810-0101 Wrench Set (Not included) 0
3 63810-0102 Locator Base 1
4 63810-0103 Repair Kit (Not included) 0
5 63819-7370 Tool Kit with Locator 1
6 63819-7375 Locator (only) REF

Tool Kit for Slip-On Wire-to-Wire Crimp Terminals
Doc No: ATS-6381973 M Release Date: 04-30-09 UNCONTROLLED COPY Page 9 of 9
Revision: B Revision Date: 10-11-10
Figur 12
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
It m Ord r No Engin ring No. D scription Quantity
1
63816-0300 63816-0300 Power Crimp ead 1
2
63819-7370 63819-7370 Tool Kit 1
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