Molex 63819-4900 Manuel utilisateur

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 1 of 8

Revision: C Revision Date: 06-30-23

INSULATION

CRIMP HEIGHT

BRUSH

STRIP LENGTH

BELL MOUTH

BEND DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP HEIGHT

TWISTING

CUT-OFF

TAB

SEAM

WIRE

Order Number

63819-4900

Application Tooling

Specification Sheet

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomic soft grip handles for comfortable crimping

Easy handling due to outstanding force ratio

A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position

This tool is IPC/WHMA-A-620 compliant

Tooling can be installed in the 63816-1915 Power Crimp Head, which is installed into the 63816-0270 (110 V) or

63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine

This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: Bulb Socket Contact Terminal for 0.50 to 0.85mm² wire

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation

Diameter

Strip Length

Available in Reel Only

mm²

In.

35438

35438-8000

0.50 to 0.85

1.8 –2.8

.071-.110

3.00 –3.60

.118 - .142

Customer to cut off terminal from reel 0.50mm (.020”) 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 Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 2 of 8

Revision: C Revision Date: 06-30-23

CONDITIONS:

After crimping, the conductor profiles should measure the following (see notes below).

Terminal

Series No.

Wire Size

Actual mm²

Conductor

Profile

Crimp Height

Crimp Width (Ref.)

In.

35438

0.50

1.00-1.10

.039-.043

1.90-2.10

.075-.083

0.85

1.20-1.30

.047-.051

1.90-2.10

.075-.083

Terminal

Series No.

Wire Size

Actual mm²

Insulation

Pull Force

Minimum

Crimp Height (Ref.)

Crimp Width (Ref.)

In.

Lb.

35438

0.50

2.65

.104

2.70-2.90

.106-.114

58.9

13.2

0.85

2.66

.105

2.70-2.90

.106-.114

98.0

22.0

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, and it should be used as the final

criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification. Refer

to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp testing.

3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force specification.

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 document.

2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height.

3. This tool is intended for the conductor sizes specified on this document. 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 6. 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.

CAUTION: Crimp only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool or die.

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 3 of 8

Revision: C Revision Date: 06-30-23

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

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

18 long BHCS and tighten in place. See Figure 1.

Locator Installation and Removal

Follow the steps below to install or replace the locator. See Figure

To install the locator

1. Position the locator with the hole over the brass pivot shaft and snap it into place.

To remove 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.

Figure 3

LOCATOR

JAWS OPEN

TERMINAL

SWING OPEN

PRESS HERE

ON LOCATOR

LOCATOR

TERMINAL IN PLACE

Figure 4

LOCATOR

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 4 of 8

Revision: C Revision Date: 06-30-23

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 4. 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 4.

4. Insert the terminal into the proper nest opening. Make sure when

choosing the nest opening, it will correspond with the A, or B

profile on the hand tool.

5. Return the locator to its original position. Insert the pre-stripped

wire. Gently touch the wire stop with the end of the wire. See

Figure 5.

6. Compress the terminal by squeezing the tool handles until the

ratchet mechanism cycle has been completed. Release handles to open the jaws.

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.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

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.

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. 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.

SWING

LOCATOR

OPEN

PRESS DOWN

ON BRASS PIVOT

SHAFT

LIFT UP

LOCATOR

JAWS

OPEN

Figure 6

WIRE

LOCATOR

IN PLACE

WIRE STOP

WIRE AGAINST STOP

Figure 5

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 5 of 8

Revision: C Revision Date: 06-30-23

4. Replace it with the proper locator by putting over the brass pivot shaft and snapping it into place.

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 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 Preload (See Figure 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.

RATCHET

RELEASE LEVER

Figure 8

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELOAD

CHECK POINT

25.4MM

SETTING WHEEL

Figure 7B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 6 of 8

Revision: C Revision Date: 06-30-23

Warranty

This hand tool is for electrical terminal crimping purposes only. This hand 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.

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 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 when operating or maintaining this tool.

4. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

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 or determine tool life:

When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out

of service and replaced.

The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 7 of 8

Revision: C Revision Date: 06-30-23

HAND

CRIMP

FRAME

TOOL KIT

APPLICATIONS FOR THE TOOL KIT AND POWER CRIMP HEAD

The chart below shows all applications for this Tool Kit and Power Crimp Head:

Tool

Order No.

Tool

Description

Crimp Head

Order No.

Crimp Head

Description

Figure

No.

63819-4900

Hand Crimp Tool

---

63816-0270

Battery Power Tool (110 V)

63816-1915

Power Crimp Head

63816-0280

Battery Power Tool (220 V)

63816-1915

Power Crimp Head

63816-1900

Electric Crimp Machine

63816-1915

Power Crimp Head

Applications for the Tool Kit and Power Crimp Head

Hand Crimp Tool

Battery Powered Tool

Electric Crimp Machine

Figure 9

Figure 10

Figure 11

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 connected to 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

TOOL KIT

LOCATOR

POWER CRIMP

HEAD

ELECTRIC CRIMP MACHINE

LOCATOR

Tool Kit for Bulb Socket Contact Crimp Terminals

Doc No: ATS-6381949HM Release Date: 01-30-09 UNCONTROLLED COPY Page 8 of 8

Revision: C Revision Date: 06-30-23

RATCHET

RELEASE SCREW

Figure 11

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

Figure 12

Application Tooling Support

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.

Item Number

Order Number

Description

Quantity

REF

63819-4900

Hand Crimp Tool

Figure 12

---

Hand Crimp Frame

63810-0101

Wrench Set (Not included)

63810-0102

Locator Base

63810-0103

Repair Kit (Not included)

---

Tool Kit

63819-4975

Locator

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