meter 9K 50212-8100 39-00-0424 50212-8000 0 20-005 0.80-1.40 031-055 1.30-1.80 .051-.071 59354-8 1 8 1 59354-8081 031-055 *6 NGTH BELL MOUTH
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Doc No: ATS-638190500 Release Date: 11-26-07 UNCONTROLLED COPY Page 1 of 7
Revision: D Revision Date: 01-26-12
INSULATION
CRIMP HEIGHT
BRUSH
STRIP
LENGTH
BELL MOUTH
BEND DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP HEIGHT
TWISTING
CUT OFF
TAB
SEAM
WIRE
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
Order No. 63819
-
05
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 as indicated
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.00mm (.079") Pitch Crimp Terminal, 24-30 AWG.
Terminal Series No.
Terminal Order No. Wire Size Insulation Diameter
Strip Length
Loose Piece Reel AWG
mm² mm In. mm In.
50212 50212-8100
39-00-0424
50212-8000
24-30
0.20-0.05
0.80-1.40
.031-055
1.30-1.80
.051-.071
59354 59354-8181
59354-8081
24-30
0.20-0.05
0.80-1.40
.031-055
1.30-1.80
.051-.071
59354-8099
Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4D
Conduclor Crimp Insulation Crimp mm In mm In. mm 0.51-0.61 .020-.024 0.51-0.61 .020-.024 0.51-0.61 .020-.024 30 005 0.51-0.61 .020-.024 Tool Qualification Notes: Reference Only. l ,_ POSTION R BUTTON
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Doc No: ATS-638190500 Release Date: 11-26-07 UNCONTROLLED COPY Page 2 of 7
Revision: D Revision Date: 01-26-12
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No
Wire Size Conductor Crimp Insulation Crimp Pull Force
Minimum Profile
Height (Ref.) Width (Ref.)
Height (Ref.)
Width (Ref.)
AWG
mm2
mm In. mm In. mm In. mm In. N Lb. 24-26 28-30
50212
24 0.20 0.51-0.61
.020-.024
1.02 .040 1.43 .056 1.40 .055 29.4
6.60 X
26 0.12 0.51-0.61
.020-.024
1.02 .040 1.43 .056 1.40 .055 19.6
4.40 X
28 0.08 0.51-0.61
.020-.024
1.02 .040 1.31 .052 1.29 .051 9.8 2.20 X
30 0.05 0.51-0.61
.020-.024
1.02 .040 1.31 .052 1.29 .051 4.9 1.10 X
59354
24 0.20 0.51-0.61
.020-.024
1.02 .040 1.43 .056 1.40 .055 29.4
6.60 X
26 0.12 0.51-0.61
.020-.024
1.02 .040 1.43 .056 1.40 .055 19.6
4.40 X
28 0.08 0.51-0.61
.020-.024
1.02 .040 1.31 .052 1.29 .051 9.8 2.20 X
30 0.05 0.51-0.61
.020-.024
1.02 .040 1.31 .052 1.29 .051 4.9 1.10 X
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.
Insulation Crimp Note:
Due to the terminal’s insulation grip design and/or
insulation diameter range, this tool uses “overlap” form
geometry in the insulation punch. This produces an
overlap insulation crimp (A620 – compliant). While the
insulation punch profile may appear “lopsided”, this is
a normal condition for this tool. See figure to the right.
(Some tools with multiple crimp pockets may not have the “overlap” profile on all pockets).
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
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.
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. See Figure 1.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
Figure 4
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Doc No: ATS-638190500 Release Date: 11-26-07 UNCONTROLLED COPY Page 3 of 7
Revision: D Revision Date: 01-26-12
RELEASE
LOCATOR BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
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.
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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
‘ LOCATOR LOWER TABS
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Doc No: ATS-638190500 Release Date: 11-26-07 UNCONTROLLED COPY Page 4 of 7
Revision: D Revision Date: 01-26-12
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
8. Remove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
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.
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.
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:
TERMINAL
Figure 6
WIRE
WIRE STOP
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Doc No: ATS-638190500 Release Date: 11-26-07 UNCONTROLLED COPY Page 5 of 7
Revision: D Revision Date: 01-26-12
MATCH
UP MARKS
FRONT BACK
Figure 9
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.
How to Adjust Tool Preload (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:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11
CAUTIONS:
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Doc No: ATS-638190500 Release Date: 11-26-07 UNCONTROLLED COPY Page 6 of 7
Revision: D Revision Date: 01-26-12
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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 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. 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.
63810-0105 S rin , Ratchet
Hand Crimp Tool For 2.00mm (.079") Pitch Crimp Terminals
Doc No: ATS-638190500 Release Date: 11-26-07 UNCONTROLLED COPY Page 7 of 7
Revision: D Revision Date: 01-26-12
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63819-0500 Hand Crimp Tool Figure 13
1 63819-0575 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
Visit our Web site at http://www.molex.com