molex 63823-8000 User manual

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638238000 - HANDTOOL CRIMP 2.5MM WW 22-28AWG
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
0638238000
0638238000
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 0638238000 - HANDTOOL CRIMP 2.5MM WW 22-28AWG
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
Doc o: ATS-6382380HM Release Date: 02-15-11 UNCONTROLLED COPY Page 1 of 6
Revision: C Revision Date: 03-27-14
INSULATION CRIMP
▲SEE NOTE
BRUSH
STRIP LENGTH
WIRE
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP HEIGHT
TWISTING
SEAM
CUT
-
OFF
TAB
BELL MOUTH
Application Toolin
Specification Sheet
Modular Crimp Head
Order No. 63823-8070
Hand Crimp Tool
Order No. 63823-8000
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
% A-620 Class 2 compliant and RoHS compliant
% 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: 2.5mm (.098") Pitch Wire to Wire Male Terminal, 22-28 AWG.
Terminal Series No.
Terminal Order No.
Wire Size

Insulation Diameter
Strip Len th



Reel
Loos
e
AWG
mm²
mm
In.
mm
In.
50397
50397
-
8000
50397
-
8100
22
-
28
0.35
-
0.08
1.05
-
1.90
0.043
-
.075
2.6
-
3.1
0.102
-
0.122
50398
50398
-
8000
50398
-
8
1
00
22
-
28
0.35
-
0.08
1.05
-
1.90
0.043
-
.075
2.6
-
3.1
0.102
-
0.122

See Conditions on page 2.
Customer to cut off terminal from reel, 0.20mm (.008”) maximum cut-off tab.
DEFINITION OF TERMS
TYPE 4A
2 / 7
2 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638238000 - HANDTOOL CRIMP 2.5MM WW 22-28AWG
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
Doc o: ATS-6382380HM Release Date: 02-15-11 UNCONTROLLED COPY Page 2 of 6
Revision: C Revision Date: 03-27-14
▲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
After crimping, the crimp profiles should measure the following (see notes on page 4).
Terminal
Order No.
Wire Size
Conductor Crimp
Insulation
Crimp
Pull Force
Minimum 

Profile
Hei ht (Ref)
Width (Ref)
Hei ht (Ref)
Width (
Max.
)
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
A
B
C
D
50397
22
0.35
0.84
-
0.89
.033
-
.035
1.20
.047
1.90
-
2.00
.075
-
.079
1.85
.073
39.2
8.8
X
24
0.20
0.76
-
0.81
.030
-
.032
1.20
.047
1.90
-
2.00
.075
-
.079
1.80
.071
29.4
6.6
X
26
0.12
0.71
-
0.76
.028
-
.030
1.20
.047
1.60
-
1.70
.063
-
.067
1.75
.069
19.6
4.4
X
28
0.08
0.67
-
0.72
.026
-
028
1.20
.047
1.60
-
1.70
.063
-
.067
1.75
.069
9.8
2.2
X
50398
22
0.35
0.84
-
0.89
.033
-
.035
1.20
.047
1.90
-
2.00
.075
-
.079
1.
85
.07
3
39.2
8.8
X
24
0.20
0.76
-
0.81
.030
-
.032
1.20
.047
1.90
-
2.00
.075
-
.079
1.80
.071
29.4
6.6
X
26
0.12
0.71
-
0.76
.02
8
-
.030
1.20
.047
1.60
-
1.
7
0
.063
-
.0
67
1.
75
.0
69
19.6
4.4
X
28
0.08
0.67
-
0.72
.026
-
028
1.20
.047
1.60
-
1.70
.063
-
.067
1.75
.069
9.8
2.2
X

To Achieve IPC
-
A
-
620 Class
2
Crimps, the following over
-
all wire insulation diameter ranges are recomme
nded:
Profile A: 1.35-1.70mm (.053-.067”) Profile B: 1.35-1.70mm (.053-.067”)
Profile C: 1.15-1.40mm (.045-.055”) Profile D: 1.15-1.40mm (.045-.055”)
Tool Qualification otes:
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.
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 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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
TERMINAL
SEATED IN
LOCATOR
SWING
LOCATOR
OPEN
Fi ure 1
HAND TOOL
OPEN
WIRE
STOP
BLADE
3 / 7
3 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638238000 - HANDTOOL CRIMP 2.5MM WW 22-28AWG
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
Doc o: ATS-6382380HM Release Date: 02-15-11 UNCONTROLLED COPY Page 3 of 6
Revision: C Revision Date: 03-27-14
WIRE
CONDUCTOR
PUNCH
TERMINAL
WIRE STOP
BLADE
Fi ure 2 Fi ure 3
WIRE
TERMINAL
LOCATOR
INSULATI
ON
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR
ANVIL
CONDUCTOR
PUNCH
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.
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/Chan e 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.
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.
M4 BHCS
PIVOT
LOCATOR
Fi ure 4
4 / 7
4 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638238000 - HANDTOOL CRIMP 2.5MM WW 22-28AWG
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
Doc o: ATS-6382380HM Release Date: 02-15-11 UNCONTROLLED COPY Page 4 of 6
Revision: C Revision Date: 03-27-14
INCORRECT
Fi ure 5
CORRECT
INCORRECT
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 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 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 / 7
5 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638238000 - HANDTOOL CRIMP 2.5MM WW 22-28AWG
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
Doc o: ATS-6382380HM Release Date: 02-15-11 UNCONTROLLED COPY Page 5 of 6
Revision: C Revision Date: 03-27-14
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
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.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Fi ure
No.
63823-8070
63816
-
0000
Hand Crimp Frame (S
hort)
/A
/A
6
63816
-
0050
Hand Crimp Frame (Long)
/A
/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
Po
w
er
Tool
638
16
-
0700
Air Power Crimp Adapter
8
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
Air Powered Tool
Fi ure
6
Fi ure
7
Fi ure
8
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT
6 / 7
6 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638238000 - HANDTOOL CRIMP 2.5MM WW 22-28AWG
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 2.5mm (.098") Pitch Wire to Wire Crimp Terminals
Doc o: ATS-6382380HM Release Date: 02-15-11 UNCONTROLLED COPY Page 6 of 6
Revision: C Revision Date: 03-27-14
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
LOCATOR
2
1
4
Fi ure 9
M4 X 8mm
LONG BHCS
3
5
6
PARTS LIST
Hand Crimp Tool
638
23
-
80
00
Item
Order Number
De
scription
Quantity
1
638
23
-
8070
Modular
Crimp
Head
1
2
63816
-
00
0
0
Hand Crimp
Frame
(
Short
)
1
3
638
23
-
80
75
Locator
1
4
63816
-
0001
Locking Pin
2
5
63600
-
0525
Handle Spring
1
6
63600
-
0520
Crimping Spring
2
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