molex 63819-4900 User manual

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
mm
In.
mm
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.)
mm
In.
mm
In.
A
B
35438
0.50
0.50
1.00-1.10
.039-.043
1.90-2.10
.075-.083
X
0.85
0.85
1.20-1.30
.047-.051
1.90-2.10
.075-.083
X
Terminal
Series No.
Wire Size
Actual mm²
Insulation
Pull Force
Minimum
Crimp Height (Ref.)
Crimp Width (Ref.)
mm
In.
mm
In.
N
Lb.
35438
0.50
0.50
2.65
.104
2.70-2.90
.106-.114
58.9
13.2
0.85
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
2.
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
OR
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
---
---
9
63816-0270
Battery Power Tool (110 V)
63816-1915
Power Crimp Head
10
63816-0280
Battery Power Tool (220 V)
63816-1915
Power Crimp Head
10
63816-1900
Electric Crimp Machine
63816-1915
Power Crimp Head
11
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
1
3
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
5
6
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
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
1
---
Hand Crimp Frame
1
2
63810-0101
Wrench Set (Not included)
0
3
63810-0102
Locator Base
1
4
63810-0103
Repair Kit (Not included)
0
5
---
Tool Kit
1
6
63819-4975
Locator
1