Molex 63828-1900 Manual de usuario

Hand Crimp Tool for Pitch SPOX Crimp Terminals

Doc. No: 6382819HM Release Date: 04-25-17 UNCONTROLLED COPY Page 1 of 7

Revision: D Revision Date: 01-08-19

Application Tooling Specification

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

Modular crimp head is removable and can be used in the Electric Crimp Machine (Order No.

63816-1500), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

Can also be used in the Battery Powered Tool Order No. 63816-0270 (110 V) or 63816-0280

(220 V), accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600)

This tool is IPC/WHMA-A-620 Class 2 compliant as indicated on page 2

This tool is RoHS compliant

SCOPE

Products: 2.50mm (.098”) Pitch SPOX Wire-to-Board and Wire-to-Wire Crimp Terminal, 22-28 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size

(2) Insulation Diameter

Strip Length

Loose Piece

(1) Reel

AWG

mm²

In.

5103

08-70-0057

08-70-0056

39-00-0188

22-28

—

1.15-1.90

.045-.075

2.60-3.20

.102-.126

08-70-0059

08-70-0058

39-00-0387

39-00-0189

08-700-0569

39-00-0388

08-700-0589

39-00-0389

39-00-0390

5263

08-70-1040

08-70-1039

39-00-0151

22-28

—

1.15-1.90

.045-.075

2.40-2.90

.094-.114

08-70-1046

08-70-1045

39-00-0159

39-00-0152

08-70-1047

39-00-0160

50802

50802-8100

50802-8000

22-28

—

1.15-1.90

.045-.075

2.60-3.20

.102-.126

50802-9101

50802-9001

(1) Customer to cut off terminal from reel: 0.30mm (.012”) maximum cutoff tab.

(2) See IPC/WHMA-A-620 conditions on page 2.

DEFINITION OF TERMS

BRUSH

BELL MOUTH

BEND UP

CONDUCTOR

CRIMP

INSULATION

CRIMP

▲SEE NOTE

STRIP

LENGTH

CRIMP HEIGHT

TWIST

BEND

DOWN

ROLL

Order Number

63828-1900

Type 4A

Hand Crimp Tool for Pitch SPOX Crimp Terminals

Doc. No: 6382819HM Release Date: 04-25-17 UNCONTROLLED COPY Page 2 of 7

Revision: D Revision Date: 01-08-19

▲Insulation Crimp Note

Due to the terminal’s insulation grip design or insulation

diameter range, this tool uses overlap form geometry in

the insulation punch. This produces an overlap insulation

crimp (A-620-compliant). Although 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.

CRIMP SPECIFICATION

After crimping, the crimp profiles should measure the following:

Terminal Series No.

Bell Mouth

Conductor Brush

In.

5103

0.20-0.50

.008-.020

0.00-1.00

.000-.039

5263

50802

Terminal Series No.

Bend Up

Bend Down

Twist

Roll

Seam

Degree Max.

5263

Seam shall not be

open and no wire allowed

out of the crimping area

5103

50802

Terminal

Series No.

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

♦♦ Profile

Height (Ref.)

Width

(Ref.)

Height

(Ref.)

Width (Ref.)

AWG

mm2

In.

Lb.

5103

—

0.73-0.80

.029-.031

1.40

.055

1.68

.066

1.80

.071

44.48

10.0

—

0.67-0.74

.026-.029

1.40

.055

1.57

.062

1.80

.071

28.91

6.5

—

0.63-0.69

.025-.027

1.40

.055

1.42

.056

1.50

.059

17.79

4.0

—

0.61-0.67

.024-.026

1.40

.055

1.42

.056

1.50

.059

11.12

2.5

5263

—

0.73-0.80

.029-.031

1.40

.055

1.68

.066

1.80

.071

44.48

10.0

—

0.67-0.74

.026-.029

1.40

.055

1.57

.062

1.80

.071

28.91

6.5

—

0.63-0.69

.025-.027

1.40

.055

1.42

.056

1.50

.059

17.79

4.0

—

0.61-0.67

.024-.026

1.40

.055

1.42

.056

1.50

.059

11.12

2.5

50802

—

0.73-0.80

.029-.031

1.40

.055

1.68

.066

1.80

.071

44.48

10.0

—

0.67-0.84

.026-.029

1.40

.055

1.57

.062

1.80

.071

28.91

6.5

—

0.63-0.69

.025-.027

1.40

.055

1.42

.056

1.50

.059

17.79

4.0

—

0.61-0.67

.024-.026

1.40

.055

1.42

.056

1.50

.059

11.12

2.5

♦♦ To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are

recommended:

Profile A: 1.20-1.60mm (.047-.063”)

Profile B: 1.15-1.50mm (.045-.059”)

Profile C: 1.15-1.30mm (.045-.051”)

Profile D: 1.05-1.20mm (.041-.047”)

Tool Qualification Notes

1. Pull force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimal crimp.

OVERLAP FORM

GEOMETRY

PUNCH

OVERLAP

INSULATION

CRIMP

WIRE

ANVIL

Hand Crimp Tool for Pitch SPOX Crimp Terminals

Doc. No: 6382819HM Release Date: 04-25-17 UNCONTROLLED COPY Page 3 of 7

Revision: D Revision Date: 01-08-19

WIRE

PUNCH

TERMINAL

WIRE STOP

BLADE

Figure 2

Figure 3

WIRE

INSULATION

PUNCH

WIRE STOP

BLADE

CONDUCTOR

PUNCH

LOCATOR

TERMINAL

INSULATION ANVIL

CONDUCTOR ANVIL

Notes

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however, crimp force is adjustable (See instructions

above). Variations in tools, terminals, wire stranding and insulation types may affect crimp

height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp

support for all insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the

only parts available for repair. If the handles or crimp tooling are damaged or worn, a new tool

must be purchased.

5. Pull force should be used as the final criterion for an acceptable crimp. Pull force is measured

with no influence from the insulation crimp. The insulation should be stripped long (1/2”) so

that the insulation grips on the terminal do not grip the wire insulation or the conductor. Refer

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

crimp testing.

6. Molex does not certify crimp hand tools.

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.

1. With the hand tool in the open position, pivot the

terminal locator open by pulling up on the locator

knob, and lift the wire stop blade. See Figure 1.

2. Insert the terminal into the correct profile until the

terminal is fully seated and stops. Make sure the wire

stop blade is fully seated on the terminal behind the

conductor grip section.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade.

5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush toward

the tip point on the wire stop blade. See Figure 2. Align the wire so that it is parallel and

sitting into the terminal. Maintain a light and constant pressure on the wire that is

seated in the terminal at all times. (Do not let go of the wire.) Be sure to hold the wire

and terminal in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Lift the wire stop blade.

8. Carefully remove the crimped terminal.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP

BLADE

Hand Crimp Tool for Pitch SPOX Crimp Terminals

Doc. No: 6382819HM Release Date: 04-25-17 UNCONTROLLED COPY Page 4 of 7

Revision: D Revision Date: 01-08-19

INCORRECT

Figure 5

CORRECT

INCORRECT

M4 BHCS

PIVOT

LOCATOR

Figure 4

Note: To maintain good brush control and a consistent bell mouth, the crimping instructions must

be followed.

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

TERMINAL LOCATOR REPLACEMENT

This section describes the procedure for changing locators:

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Place the locator on the hand tool. Install the M4 BHCS. See Figure 4.

2. Tighten the screw just enough to hold the locator. Make sure the locator can still float freely

with hand pressure.

3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated

and stops. Then, gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place, and slowly tighten the M4 BHCS.

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 a 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 the 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.

Hand Crimp Tool for Pitch SPOX Crimp Terminals

Doc. No: 6382819HM Release Date: 04-25-17 UNCONTROLLED COPY Page 5 of 7

Revision: D Revision Date: 01-08-19

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 lifting the ratchet release lever. See Figure 9.

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, Molex 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: Repetitive use of this tool should be avoided.

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 at all times.

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

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and

tooling.

Hand Crimp Tool for Pitch SPOX Crimp Terminals

Doc. No: 6382819HM Release Date: 04-25-17 UNCONTROLLED COPY Page 6 of 7

Revision: D Revision Date: 01-08-19

APPLICATIONS FOR THE MODULAR CRIMP HEAD

WARNING: NEVER operate, service, install or adjust this modular crimp head without proper

instruction and without first reading and understanding the instructions in the proper manual

or specification sheet. See chart below for the correct manual or specification sheet.

WARNING: NEVER install tooling or service this tool while it is plugged into any power

source. Disconnect the power by unplugging, or turn off the actuator from its power source.

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.

The chart below shows all applications for this modular crimp head:

Tool

Order No.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63816-0000

Hand Crimp Frame (Short)

—

63816-0050

Hand Crimp Frame (Long)

—

63816-0270

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0280

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-1500

Electric Crimp Machine

63816-0600

Battery Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Electric Crimp Machine

Figure 6

Figure 7

Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

ELECTRIC

CRIMP

MACHINE

MODULAR

CRIMP HEAD

BATTERY

POWER CRIMP

ADAPTER

Hand Crimp Tool for Pitch SPOX Crimp Terminals

Doc. No: 6382819HM Release Date: 04-25-17 UNCONTROLLED COPY Page 7 of 7

Revision: D Revision Date: 01-08-19

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 8mm

LONG BHCS

PARTS LIST

Item

Order Number

Description

Quantity

63828-1970

Modular Crimp Head

63816-0000

Hand Crimp Frame (Short)

63828-1975

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Application Tooling Support

Phone: (402) 458-TOOL (8665)

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.

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