molex 63823-6800 User manual

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
Excellent Integrated System Limited
Excellent Integrated System Limited
Stocking Distributor
Stocking Distributor
Click to view price, real time Inventory, Delivery & Lifecycle Information:
Click to view price, real time Inventory, Delivery & Lifecycle Information:
Molex Connector Corporation
Molex Connector Corporation
0638236800
0638236800
For any questions, you can email us directly:
For any questions, you can email us directly:
[email protected]
[email protected]
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
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
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
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
24
26
28
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
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3 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
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
4.
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
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
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
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
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
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
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
7 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN
Contact us: [email protected] Website: www.integrated-circuit.com
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
2
Figure 13
1
3
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
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