molex 63828-1900 User manual

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
mm
In.
mm
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
mm
In.
mm
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.
Degree Max.
5263
4
2
8
8
Seam shall not be
open and no wire allowed
out of the crimping area
5103
4
4
3
8
50802
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.
A
B
C
D
5103
22
—
0.73-0.80
.029-.031
1.40
.055
1.68
.066
1.80
.071
44.48
10.0
X
24
—
0.67-0.74
.026-.029
1.40
.055
1.57
.062
1.80
.071
28.91
6.5
X
26
—
0.63-0.69
.025-.027
1.40
.055
1.42
.056
1.50
.059
17.79
4.0
X
28
—
0.61-0.67
.024-.026
1.40
.055
1.42
.056
1.50
.059
11.12
2.5
X
5263
22
—
0.73-0.80
.029-.031
1.40
.055
1.68
.066
1.80
.071
44.48
10.0
X
24
—
0.67-0.74
.026-.029
1.40
.055
1.57
.062
1.80
.071
28.91
6.5
X
26
—
0.63-0.69
.025-.027
1.40
.055
1.42
.056
1.50
.059
17.79
4.0
X
28
—
0.61-0.67
.024-.026
1.40
.055
1.42
.056
1.50
.059
11.12
2.5
X
50802
22
—
0.73-0.80
.029-.031
1.40
.055
1.68
.066
1.80
.071
44.48
10.0
X
24
—
0.67-0.84
.026-.029
1.40
.055
1.57
.062
1.80
.071
28.91
6.5
X
26
—
0.63-0.69
.025-.027
1.40
.055
1.42
.056
1.50
.059
17.79
4.0
X
28
—
0.61-0.67
.024-.026
1.40
.055
1.42
.056
1.50
.059
11.12
2.5
X
♦♦ 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)
—
—
6
63816-0050
Hand Crimp Frame (Long)
—
—
6
63816-0270
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
7
63816-0280
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
7
63816-1500
Electric Crimp Machine
63816-0600
Battery Power Crimp Adapter
8
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
2
1
4
Figure 9
M4 X 8mm
LONG BHCS
3
5
6
PARTS LIST
Item
Order Number
Description
Quantity
1
63828-1970
Modular Crimp Head
1
2
63816-0000
Hand Crimp Frame (Short)
1
3
63828-1975
Locator
1
4
63816-0001
Locking Pin
2
5
63600-0525
Handle Spring
1
6
63600-0520
Crimping Spring
2
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.