MOLEX 0638238075

Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
Modular Crimp Head
Order No. 63823-8070
Application Tooling
Specification Sheet
TYPE 4A
Hand Crimp Tool
Order No. 63823-8000
FEATURES
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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
A-620 Class 3 compliant and RoHS compliant
Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: 2.5mm (.098") Pitch Wire to Wire Terminal, 22-28 AWG.
Wire Size
Insulation Diameter
Strip Length
Terminal Terminal Order No.
Series No.
Reel
AWG
mm²
mm
In.
mm
In.
50397
50397-8000
22-28 0.35-0.08 1.05-1.90 0.043-.075 2.6-3.1 0.102-0.122
Follow the Cut-Off Tab specifications on Applicator specification sheets.
See Conditions on page 2.
DEFINITION OF TERMS
BEND UP
ROLLING
SEAM
STRIP
LENGTH
CONDUCTOR
CRIMP
BRUSH
TWISTING
BEND
DOWN
INSULATION CRIMP
▲SEE NOTE
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Doc No: ATS-6382380HM
Revision: A
Release Date: 02-15-11
Revision Date: 02-15-11
UNCONTROLLED COPY
Page 1 of 6
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design and/or
insulation diameter range, this tool uses “overlap”
form geometry in the insulation punch. This
produces an overlap insulation crimp (A620 –
compliant). While 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).
OVERLAP FORM GEOMETRY
PUNCH
OVERLAP
INSULATION
CRIMP
CRIMP SPECIFICATION
WIRE
ANVIL
After crimping, the crimp profiles should measure the following (see notes on page 4).
Conductor Crimp
Insulation Crimp
Pull Force
Profile
Terminal Wire Size
Height (Ref)
Width (Ref)
Height (Ref)
Width (Max.) Minimum
Order No.
AWG mm2 mm
In.
mm In.
mm
In.
mm
In.
N Lb. A B C D
22 0.35 0.84-0.89 .033-.035 1.20 .047 1.60-1.80 .063-.074 1.80. .071 39.2 8.8 X
24 0.20 0.76-0.81 .030-.032 1.20 .047 1.60-1.80 .063-.074 1.80. .071 29.4 6.6
X
50397
26 0.12 0.71-0.76 .028-.030 1.20 .047 1.60-1.80 .063-.074 1.80. .071 19.6 4.4
X
28 0.08 0.67-0.72 .026-028 1.20 .047 1.60-1.80 .063-.074 1.80. .071 9.8 2.2
X
To Achieve IPC-A-620 Class 3 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile A: 1.05mm (.041”) maximum-Up to the maximum terminal rating 1.90mm (.075”).
Profile B: 1.10-1.90mm (.043-.075”)
Profile C: 1.10--1.75mm (.043-.069”)
Profile D: 1.20-1.75mm (.047-.069”)
Tool Qualification Notes:
1. Pull Force should be measured with no
influence from the insulation crimp.
2. The above specifications are guidelines to
an optimum crimp.
Τ
HAND TOOL
OPEN
SWING
LOCATOR
OPEN
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.
WIRE
STOP BLADE
TERMINAL
SEATED IN
LOCATOR
1. With the hand tool in the open position, pivot
Figure 1
the terminal locator open by pulling up on the
locator knob and lift the wire stop blade up.
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.
Doc No: ATS-6382380HM
Revision: A
Release Date: 02-15-11
Revision Date: 02-15-11
UNCONTROLLED COPY
Page 2 of 6
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush towards 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 up.
8. Carefully remove the crimped terminal.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be
followed.
WIRE STOP
BLADE
TERMINAL
CONDUCTOR
PUNCH
WIRE STOP
BLADE
INSULATION
PUNCH
CONDUCTOR
PUNCH
LOCATOR
WIRE
TERMINAL
WIRE
Figure 2
Figure 3
INSULATION
ANVIL
CONDUCTOR
ANVIL
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.
Terminal Locator Replacement/Change Over
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 proper locator, (See Chart on page 2), on the hand tool.
Install the M4 BHCS. See Figure 4.
2. Tighten the screw enough to hold the locator. Make sure the locator
can still float freely with hand pressure.
M4 BHCS
3. Insert the proper terminal fully into the correct profile slot until the
Figure 4
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.
Doc No: ATS-6382380HM
Revision: A
Release Date: 02-15-11
Revision Date: 02-15-11
UNCONTROLLED COPY
PIVOT LOCATOR
Page 3 of 6
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
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
INCORRECT
CORRECT
INCORRECT
tool.
3. Make certain all pins; pivot points and bearing surfaces
Figure 5
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 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 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, we 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 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.
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 is damaged or worn, a new tool must be purchased.
Doc No: ATS-6382380HM
Revision: A
Release Date: 02-15-11
Revision Date: 02-15-11
UNCONTROLLED COPY
Page 4 of 6
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so 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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
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 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.
Modular Crimp Head
Order No.
63823-8070
Tool
Tool
Adapter
Adapter
Figure
Order no.
Description
Order No.
Description
No.
63816-0000 Hand Crimp Frame (Short)
N/A
N/A
6
63816-0050 Hand Crimp Frame (Long)
N/A
N/A
6
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter
7
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter
7
63816-0100
Air Power Tool
63816-0700
Air Power Crimp Adapter
8
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
MODULAR
CRIMP
HEAD
LOCKING
PINS
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT
Doc No: ATS-6382380HM
Revision: A
LOCKING
PINS
AIR POWER
CRIMP
ADAPTER
BATTERY
POWERED
TOOL
LOCKING
PINS
AIR
POWER
TOOL
Figure 7
Release Date: 02-15-11
Revision Date: 02-15-11
MODULAR
CRIMP HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING PINS
Figure 6
Air Powered Tool
UNCONTROLLED COPY
Figure 8
Page 5 of 6
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
PARTS LIST
Hand Crimp Tool 63823-8000
Item Order Number
Description
Quantity
1
63823-8070
Modular Crimp Head
1
2
63816-0000
Hand Crimp Frame (Short)
1
3
63823-8075
Locator
1
4
63816-0001
Locking Pin
2
5
63600-0525
Handle Spring
1
6
63600-0520
Crimping Spring
2
5
HANDLE
SPRING
2
M4 X 8mm
LONG BHCS
RATCHET
RELEASE LEVER
3
LOCATOR
Figure 9
4
1
6
CRIMPING
SPRING (2)
http://www.molex.com
Doc No: ATS-6382380HM
Revision: A
Release Date: 02-15-11
Revision Date: 02-15-11
UNCONTROLLED COPY
Page 6 of 6