molex 35768 Series User manual

Hand Crimp Tool for .090 (2.3mm²) Slip-On Receptacles
Doc o: ATS-6381952HM Release Date: 12-04-08 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 08-11-10
INSULATION
CRIMP
▲
SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Application Tooling
Speci ication Sheet
Modular Crimp Head
Order No. 63819-5270
Hand Crimp Tool
Order No. 63819-5200
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 use in the Air Powered Tool Order o.63816-0100,
accompanied by Air Powered Crimp Adapter (Order o. 63816-0700).
% Can also be used in the Battery Powered Tool Order o.63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order o. 63816-0600).
SCOPE
Products: .090 (2.3mm²) Slip-On Receptacle Terminal for AVSS 0.3 – 0.5mm² wire.
Terminal Series No.
Terminal Order No. Wire Size and Type Insulation Diameter Strip Length
Available in Reel only mm² (AVSS) mm In. mm In.
35768 35768-0110 35768-0120 0.30–0.50 1.40-1.70 .055-.067 5.00-5.60 .197-.236
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 4A

Hand Crimp Tool for .090 (2.3mm²) Slip-On Receptacles
Doc o: ATS-6381952HM Release Date: 12-04-08 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 08-11-10
▲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).
CRIMP SPECIFICATION
Terminal Series No. Bell Mouth Bend up Bend down Twist Roll Conductor Brush
mm In. Degree Degree mm In.
35768 0.30–0.60 .012-.024 3 3 3 5 0.30–0.80 .012-.031
Seam: Seam shall not be open and no wire allowed out of the crimping area.
After crimping, the crimp profiles should measure the following (See notes on page 4).
Terminal
Series No.
Wire Size
(AVSS)
Conductor Insulation Pull Force
Minimum Pro ile mm²
Crimp Height
(Re )
Crimp Width
(Re )
Crimp Height
(Re )
Crimp Width
Maximum(Re )
mm2 mm In. mm In. mm In. mm In. N Lb 0.3 0.5
35768 0.30 0.90–1.00
.035-.039 1.80 .071 2.22 .087 2.30 .091 58.8 13.2 X
0.50 1.00–1.10 .039-.043 1.80 .071 2.27 .089 2.30 .091 58.8 13.2 X
Τ
ΤΤ
Τ Tool Quali ication Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
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. Lift the wire stop blade up.
2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.
3. Bring down the wire stop blade.
4. Slide the pre-stripped wire into the wire stop blade. See Figure 1. Be sure to hold the wire in place until the
terminal is fully crimped. See Figure 2.
5. Close the tool until the ratchet releases, the tool handles will then spring open.
6. Lift the wire stop blade up if it is still in down position.
7. Carefully remove the crimped terminal.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for .090 (2.3mm²) Slip-On Receptacles
Doc o: ATS-6381952HM Release Date: 12-04-08 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 08-11-10
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 lifting the ratchet release lever. See Figure 6.
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.
TERMINAL
PRE-STRIPPED
WIRE
LOCATOR
Figure 1
WIRE STOP
BLADE
Figure 2
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE

Hand Crimp Tool for .090 (2.3mm²) Slip-On Receptacles
Doc o: ATS-6381952HM Release Date: 12-04-08 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 08-11-10
CAUTIONS:
1. Manually powered hand tools are intended for low volume or field repair. This tool is OT 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.
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.

Hand Crimp Tool for .090 (2.3mm²) Slip-On Receptacles
Doc o: ATS-6381952HM Release Date: 12-04-08 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 08-11-10
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POWER
CRIMP
ADAPTER
Applications or 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.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63819-5270
63816-0000 Hand Crimp Frame (Short) /A /A 3
63816-0050 Hand Crimp Frame (Long) /A /A 3
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 5
Applications or the Modular Crimp Head
Hand Crimp Tool Battery Powered Tool Air Powered Tool
Figure 3 Figure 4 Figure 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for .090 (2.3mm²) Slip-On Receptacles
Doc o: ATS-6381952HM Release Date: 12-04-08 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 08-11-10
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
2
5
1
M4 x 14
LONG BHCS
PARTS LIST
Hand Crimp Tool 63819-5200
Item Order Number Description Quantity
1 63819-5270 Modular Crimp Head 1 (Ref)
2 63816-0050 Hand Crimp Frame (Long) 1 (Ref)
3 63819-5275 Locator 1
4 63816-0001 Locking Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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