Molex 63823-6800 Manuale utente

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Excellent Integrated System Limited

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Molex Connector Corporation

0638236800

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1 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp in

Doc No: ATS-638236800 Release Date: 10-25-10 UNCONTROLLED COPY age 1 of 7

Revision: A Revision Date: 10-25-10

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

HAND CRIMP

TOOL

Application Tooling

Specification S eet Order No. 63823-6800

FEATURES

 A full cycle ratcheting hand tool ensures complete crimps

 Ergonomic soft grip handles for comfortable crimping

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

 Right and Left handed applications

 This tool is I C/WHMA A-620 Class 2 compliant

 This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

roducts: 2.5 (.098”) Board-In Connector, Mini Crimp in, 22-28 AWG.

Terminal

Series No.

Terminal Order No. Wire Size Insulation Diameter Strip Lengt

IPC/WHMA-A620 Terminal

Loose Piece





Reel AWG

mm² mm In. mm In. mm In.

5394 08-70-1044 08-70-1043

22-28

.35-.08

1.20-1.50

.047-.059

1.20-1.70

.047-.067

2.10-2.70

.083-.106

Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.

To achieve optimum I C-A620 Class 2 insulation crimps, use this insulation OD range.

Overall insulation OD specification for terminal.

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 4D

2 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp in

Doc No: ATS-638236800 Release Date: 10-25-10 UNCONTROLLED COPY age 2 of 7

Revision: A Revision Date: 10-25-10

CONDITIONS:

After crimping, the conductor profile should measure the following.

Terminal Series No.

Wire Size Conductor Profile

Crimp Heig t Crimp Widt (Ref)

AWG

mm2

mm In. mm In. 22

5394

22 0.35 0.69-0.74

.027-.029

1.25 .049 X

24 0.20 0.61-0.66

.024-.026

1.25 .049 X

26 0.12 0.54-0.59

.021-.023

1.25 .049 X

28 0.08 0.51-0.56

.020-.022

1.25 .049 X

Terminal Series No.

Wire Size Insulation (Ref) Pull Force Minimum

Crimp Heig t

Crimp Widt

AWG

mm2

mm In. mm In. N Lb.

5394

22 0.35 1.55 .061 1.85 .073 39.10 8.79

24 0.20 1.45 .057 1.85 .073 29.40 6.61

26 0.12 1.35 .053 1.85 .073 19.60 4.41

28 0.08 1.25 .049 1.85 .073 9.80 2.20

Tool Qualification Notes:

1. ull Force should be measured with no influence from the insulation crimp.

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

▲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).

Note:

A crimp height chart is provided with this

manual as Reference Only. Due to the wide range of wires, strands, insulation diameters, and durometers

available, actual crimp height measurements may very slightly. An occasional, destructive, pull force test should be

performed to check hand tool crimp. ull Force value Must exceed the Minimum pull force specifications listed.

OPERATION

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

occur to the tool or die.

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. See Figure 1.

MAKE SURE

CENTER OF

LOCATOR

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

3 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp in

Doc No: ATS-638236800 Release Date: 10-25-10 UNCONTROLLED COPY age 3 of 7

Revision: A Revision Date: 10-25-10

RELEASE

LOCATOR BUTTON

TERMINAL Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

WIRE TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE STOP IS PART OF

THE LOCATOR

Figure 5

PRE-STRIPPED

WIRE

TERMINAL

Crimping Terminals

1. Select the desired terminal listed in the

preceding charts.

2. Make sure the center of the locator is in the

down position. With the locator attached,

push the locator button on the back of the

hand tool to bring the locator forward through

the tooling. See Figure 2.

3. While holding the locator button in, load the

terminal into the proper nest opening in the

locator based on the wire gauge or terminal

type markings on the hand tooling. See

Figure 3.

4. Release the locator button, allowing the locator to return to the crimping

position.

5. Close the tool handle until the first ratchet position engages. See Figure

6. Insert the properly stripped wire through the terminal and against the

wire stop. See Figure 5.

7. Crimp the terminal by squeezing the tool handles until the ratchet

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

jaws.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

4 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp in

Doc No: ATS-638236800 Release Date: 10-25-10 UNCONTROLLED COPY age 4 of 7

Revision: A Revision Date: 10-25-10

Figure 8

PUSH ON

HANDLE

PULL OPEN

TOOLING TOOLING

M3 BHCS

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

8. Remove the crimped terminal from the terminal

locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper

crimp location.

10. On some large O.D. wires, it may not be possible to

insert the wire with the tool partially closed. Those

wires should be inserted with the hand tool in the

open position. Insert the wire above the terminal in

the punch and against the wire stop then close the

tool. See Figure 6.

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. Squeeze gently on the lower area shown in

Figure 7A with your thumb and index finger.

The lower tabs of the locator should disengage

from the hand tool.

3. Lift and pull away from the hand tool. The top

locator hooks should slip out of the top slots

easily. See Figure 7A.

4. To reinstall the new locator, make sure the hand

tool is in the open position.

5. ress the red insert down as far as it will go as

shown in Figure 7B.

6. Holding onto the lower part of the locator with your

thumb and index finger, insert the locators top

hooks (2) into the hand tool top slots.

7. Rotate the locator down and press the lower tabs

into the two bottom slots of the hand tool. To

secure the locator into place, the lower tabs must

snap into place on the hand tool frame.

TERMINAL

Figure 6

WIRE

WIRE STOP

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

Figure 1

HANDLE WILL

SPRING OPEN

SQUEEZE

HAND

LES

Figure 7B

5 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp in

Doc No: ATS-638236800 Release Date: 10-25-10 UNCONTROLLED COPY age 5 of 7

Revision: A Revision Date: 10-25-10

Rig t or Left Hand Operation

This hand tool has an added feature that can be

converted from a right handed application to a left

handed application. It is necessary to reverse the

tooling if using the left handed application along with the

locator. Follow the steps below:

1. The locator must be removed before reversing the

tooling.

2. Remove the M3 BHCS which is holding the upper tooling.

3. Flip the upper tooling to the opposite side and replace the M3 BHCS.

Make sure the small markings on the front and back of the hand tool

frame match up and are on the outside of the hand tool frame. See

Figure 8 and 9.

4. Do the same thing with the lower tooling and tighten the M3 screws. Be

sure the small markings line up.

5. Reinstall the locator by following the Instructions in the locator

replacement section.

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 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 pressing up on the ratchet release lever in the movable handle. See Figure

11.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

RATCHET RELEASE

LEVER

Figure 11

MATCH

UP MARKS

FRONT BACK

Figure 9

6 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp in

Doc No: ATS-638236800 Release Date: 10-25-10 UNCONTROLLED COPY age 6 of 7

Revision: A Revision Date: 10-25-10

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

How to Adjust Tool Preload (See

Figure 12)

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. Hold the hand tool in the palm of your

hand as shown in Figure 10. Using

the index finger squeeze the link

towards the top of the hand tool

frame. This will release the preload

adjustment wheel.

2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.

To decrease handle force rotate the setting wheel clockwise (CW).

3. Release the link to lock the setting wheel in place.

4. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.

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

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.

Certification

Molex does not certify or re-certify hand tools but rather supplies the following guidelines for customers to re-certify

hand tools.

% This tool is qualified to pull force only. See the Molex web site for the Quality Crimp Handbook for more

information on pull testing.

% If the tool does not meet minimum pull force values, handle preload should be increased and the pull test

rerun, (See How to Adjust reload).

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

7 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN

Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp in

Doc No: ATS-638236800 Release Date: 10-25-10 UNCONTROLLED COPY age 7 of 7

Revision: A Revision Date: 10-25-10

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number Order Number Description Quantity

REF 63823-6800 Hand Crimp Tool Figure 13

1 63823-6875 Locator Assembly 1

2 63810-0104 Spring, Return 1

3 63810-0105 Spring, Ratchet 1

http://www.molex.com

8 / 8

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