192840034

192840034 MOLEX | Alldatasheet

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Doc No. 19284-0034 Release Date: 10-17-03 UNCONTROLLED COPY Page 1 of 5 Revision: A Revision Date: 10-17-03 Hand Crimp Tool Operating Instruction Sheet And Specifications Part No. 19284-0034 Eng. No. E-406

FEATURES

/c140/c32 Heavy-duty cable crimping tool with hand held precision /c140/c32 Perfect for maintenance and lower volume crimping /c140/c32 3 Interchangeable Die Inserts which are stored in the handle and covers the full wire range /c140/c32 Long handles provide maximum mechanical advantage which reduces operator fatigue SCOPE Eyelet Style Copper Lug Terminals 8-4/0 AWG. Testing Mechanical The tensile test, or pull test is, a means of evaluating the mechanical properties of the crimped connections. The following chart shows the UL Specifications for various wire sizes. The tensile strength is shown in pounds and indicates the minimum acceptable force to break or separate the terminal from the conductor. Wire Size (AWG) *UL - 486 A 8 90 6 100 4 140 2 180 1 200 1/0 250 2/0 300 3/0 350 4/0 450 *UL - 486 A - Terminals (Copper conductors only) The following is a partial list of the product part numbers and their specifications that this tool is designed to crimp. We will be adding to this list and an up to date copy is available on www.molex.com. Wire Size: 8 8.50 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0223 BCL-810-PL .437 11.09 Insert A 19221-0224 BCL-814-PL .437 11.09 Insert A 19221-0225 BCL-8516-PL .437 11.09 Insert A 19221-0226 BCL-838-WP-PL .437 11.09 Insert A 19221-0408 BCL-810 .437 11.09 Insert A 19221-0409 BCL-814 .437 11.09 Insert A 19221-0410 BCL-838-WP .437 11.09 Insert A 19221-0411 BCL-8516 .437 11.09 Insert A 19221-0414 BCL-812-XWP-PL .437 11.09 Insert A Wire Size: 8 8.50 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0415 BCL-812-XWP .437 11.09 Insert A 19221-0481 BCL-838-XWP .437 11.09 Insert A 19221-0482 BCL-8516-WP .437 11.09 Insert A 19221-0483 BCL-8516-WP-PL .437 11.09 Insert A 19221-0484 BCL-838-XWP-PL .437 11.09 Insert A Wire Size: 6 16.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert

Doc No. 19284-0034 Release Date: 10-17-03 UNCONTROLLED COPY Page 2 of 5 Revision: A Revision Date: 10-17-03 Wire Size: 6 16.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0227 BCL-614-WP-PL .437 11.09 Insert A 19221-0228 BCL-6516-WP-PL .437 11.09 Insert A 19221-0229 BCL-638-WP-PL .437 11.09 Insert A 19221-0384 BCL-638-WP .437 11.09 Insert A 19221-0406 BCL-614-WP .437 11.09 Insert A 19221-0407 BCL-6516-WP .437 11.09 Insert A 19221-0416 BCL-612-XWP-PL .437 11.09 Insert A 19221-0417 BCL-612-XWP .437 11.09 Insert A 19221-0424 BCL-610-PL .437 11.09 Insert A 19221-0425 BCL-610 .437 11.09 Insert A 19221-0492 BCL-6561-PL .437 11.09 Insert A 19221-0493 BCL-6561 .437 11.09 Insert A 19221-0494 BCL-614 .437 11.09 Insert A 19221-0495 BCL-6141-PL .437 11.09 Insert A 19221-0568 BCL-638-XWP-PL .437 11.09 Insert A 19221-0569 BCL-638-XWP .437 11.09 Insert A Wire Size: 4 25.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0230 BCL-414-PL .500 12.70 Insert A 19221-0231 BCL-4516-PL .500 12.70 Insert A 19221-0232 BCL-438-PL .500 12.70 Insert A 19221-0383 BCL-438 .500 12.70 Insert A 19221-0404 BCL-414 .500 12.70 Insert A 19221-0405 BCL-4516 .500 12.70 Insert A 19221-0451 BCL-410 .500 12.70 Insert A 19221-0452 BCL-410-PL .500 12.70 Insert A 19221-0453 BCL-412 .500 12.70 Insert A 19221-0454 BCL-412-PL .500 12.70 Insert A 19221-0456 BCL-438-WP-PL .500 12.70 Insert A 19221-0457 BCL-438-XWP-PL .500 12.70 Insert A 19221-0458 BCL-438-WP .500 12.70 Insert A 19221-0459 BCL-438-XWP .500 12.70 Insert A 19221-0460 BCL-4516-WP-PL .500 12.70 Insert A 19221-0461 BCL-4516-WP .500 12.70 Insert A Wire Size: 2 35.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0233 BCL-2516-PL .562 14.27 Insert C 19221-0235 BCL-238-PL .562 14.27 Insert C 19221-0236 BCL-212-WP-PL .562 14.27 Insert C 19221-0380 BCL-238 .562 14.27 Insert C 19221-0399 BCL-212-WP .562 14.27 Insert C 19221-0400 BCL-2516 .562 14.27 Insert C 19221-0418 BCL-214-PL .562 14.27 Insert C 19221-0419 BCL-214 .562 14.27 Insert C Wire Size: 1 42.4 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0237 BCL-1516-PL .625 15.87 Insert C 19221-0238 BCL-138-PL .625 15.87 Insert C 19221-0239 BCL-112-PL .625 15.87 Insert C 19221-0378 BCL-138 .625 15.87 Insert C 19221-0395 BCL-112 .625 15.87 Insert C 19221-0396 BCL-1516 .625 15.87 Insert C 19221-0420 BCL-114-PL .625 15.87 Insert C Wire Size: 1 42.4 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0421 BCL-114 .625 15.87 Insert C Wire Size: 1/0 50.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0240 BCL-10516-PL .687 17.44 Insert B 19221-0241 BCL-1038-PL .687 17.44 Insert B 19221-0242 BCL-1012-PL .687 17.44 Insert B 19221-0377 BCL-1038 .687 17.44 Insert B 19221-0393 BCL-1012 .687 17.44 Insert B 19221-0394 BCL-10516 .687 17.44 Insert B 19221-0422 BCL-1014-PL .687 17.44 Insert B 19221-0423 BCL-1014 .687 17.44 Insert B 19221-0436 BCL-1012-WP-PL .687 17.44 Insert B 19221-0437 BCL-1012-WP .687 17.44 Insert B 19221-0440 BCL-1038-WP-PL .687 17.44 Insert B 19221-0441 BCL-1038-WP .687 17.44 Insert B Wire Size: 2/0 70.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0234 BCL-2014-PL .687 17.44 Insert B 19221-0243 BCL-20516-PL .687 17.44 Insert B 19221-0244 BCL-2038-PL .687 17.44 Insert B 19221-0245 BCL-2012-PL .687 17.44 Insert B 19221-0249 BCL-2014 .687 17.44 Insert B 19221-0379 BCL-2038 .687 17.44 Insert B 19221-0397 BCL-2012 .687 17.44 Insert B 19221-0398 BCL-20516 .687 17.44 Insert B Wire Size: 3/0 95.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0246 BCL-30516-PL .750 19.05 No Insert 19221-0247 BCL-3038-PL .750 19.05 No Insert 19221-0248 BCL-3012-PL .750 19.05 No Insert 19221-0381 BCL-3038 .750 19.05 No Insert 19221-0401 BCL-3012 .750 19.05 No Insert 19221-0402 BCL-30516 .750 19.05 No Insert 19221-0478 BCL-3014 .750 19.05 No Insert 19221-0570 BCL-3014-PL .750 19.05 No Insert Wire Size: 4/0 120.0 mm² Wire Strip Length Terminal No. Terminal Eng No. (REF) In mm Die Insert 19221-0250 BCL-4038-PL .812 20.62 No Insert 19221-0251 BCL-4012-PL .812 20.62 No Insert 19221-0371 BCL-4038-PL (.625) .812 20.62 No Insert 19221-0372 BCL-4012-PL (.625) .812 20.62 No Insert 19221-0374 BCL-4038 (.625) .812 20.62 No Insert 19221-0375 BCL-4012 (.625) .812 20.62 No Insert 19221-0382 BCL-4038 .812 20.62 No Insert 19221-0403 BCL-4012 .812 20.62 No Insert 19221-0412 BCL-40516-PL .812 20.62 No Insert 19221-0413 BCL-40516 .812 20.62 No Insert 19221-0502 BCL-40516 (.625) .812 20.62 No Insert 19221-0503 BCL-40516-PL (.625) .812 20.62 No Insert

Doc No. 19284-0034 Release Date: 10-17-03 UNCONTROLLED COPY Page 3 of 5 Revision: A Revision Date: 10-17-03

Doc No. 19284-0034 Release Date: 10-17-03 UNCONTROLLED COPY Page 4 of 5 Revision: A Revision Date: 10-17-03 INTRODUCTION Hand Crimp Tool 19284-0034 (E-406) is used to crimp heavy-duty copper lug terminals onto the wire sizes, given in the charts 1 and 2.

DESCRIPTION

The tool consists of jaws, handles, and three interchangeable die inserts. Each die insert is marked with an alphabetic letter to correspond with the wire size being used. See terminal part number for correct insert. Note: On some standard and minimum gauge cables, re-crimping the assembly with the next smaller insert may be advisable for maximum circuit efficiency OPERATION Crimping Terminals 1. Strip the wire to the dimension given in the preceding terminal lists. 2. Install the proper die insert onto the jaw. The three interchangeable die inserts are changed by removing the holding screw on the handle and installing the proper die insert into the jaws of the tool. 3. Insert the properly stripped wire into the terminal barrel. 4. Center the terminal barrel with the wire in the proper die insert. Make sure that the pad or bottom side of the terminal barrel faces the tool indenter. 5. Now close the crimp tool handles completely and release. Open the handles and remove the crimped terminal. 6. Inspect the product for a quality crimp. Hand held crimping tools are intended for low volume, prototyping, or repair requirements only. Caution: Repetitive use of this tool should be avoided.

Doc No. 19284-0034 Release Date: 10-17-03 UNCONTROLLED COPY Page 5 of 5 Revision: A Revision Date: 10-17-03 Figure 2 JAWS DIE INSERT INDENTOR INTERCHANGEABLE DIE INSERTS DIE INSERT MARKING HANDLES PARTS LIST Item Order No Description Quantity 1 19284- 0034 Hand Crimp Tool (Fig. 2) Molex Application Tooling Group 1150 E. Diehl Road Naperville, IL 60563 Tel: (630) 969-4550 Fax: (630) 505-0049