molex 63823-8700 User guide

Chipsmall Limited consists of a professional team with an average of over 10 year of expertise in the distribution
of electronic components. Based in Hongkong, we have already established firm and mutual-benefit business
relationships with customers from,Europe,America and south Asia,supplying obsolete and hard-to-find components
to meet their specific needs.
With the principle of “Quality Parts,Customers Priority,Honest Operation,and Considerate Service”,our business
mainly focus on the distribution of electronic components. Line cards we deal with include
Microchip,ALPS,ROHM,Xilinx,Pulse,ON,Everlight and Freescale. Main products comprise
IC,Modules,Potentiometer,IC Socket,Relay,Connector.Our parts cover such applications as commercial,industrial,
and automotives areas.
We are looking forward to setting up business relationship with you and hope to provide you with the best service
and solution. Let us make a better world for our industry!
Contact us
Tel: [phone] Fax: [phone]
Email & Skype: [email protected]om Web: www.chipsmall.com
Address: A1208, Overseas Decoration Building, #122 Zhenhua RD., Futian, Shenzhen, China
  

HandCrimpToolFor3.50(.138”)WiretoWireConnector,CrimpPin
Doc o:ATS638238700 ReleaseDate:071311 Page1of7
Revision:A RevisionDate:071311






















 !"!#$%&'%(&)**

+

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IPC/WHMAA620Class2compliant
ThistoolisRoHScompliant,howeverRoHScompliantisnotrequired


Products:3.50(.138”)WiretoWireConnector,CrimpPin,1824AWG.

!,
!-#

!,!"!# !. -/,! ! 
!,012
-



 

,,3 ,, # ,, #
50419 504199101 504199001

1824

0.870.20

1.403.00

.055.118

3.003.50

.118.138

Customertocutoffterminalfromreel:0.30mm(.012”)maximumCutoffTab.
ote:TerminalwillaccommodatetheUL1007andUL1569wires.
(1)

OverallinsulationODspecificationforterminal.

++








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4

HandCrimpToolFor3.50(.138”)WiretoWireConnector,CrimpPin
Doc o:ATS638238700 ReleaseDate:071311 Page2of7
Revision:A RevisionDate:071311

5

Aftercrimping,theconductorprofileshouldmeasurethefollowing.
!,!-#

!. "/! !
!,  !," 02



,,'

,, # ,, # 1&

'*

''

'4

50419
18 0.87 1.181.28

.046.050

1.75 .069 X   
20 0.50 1.051.15

.041.045

1.75 .069  X  
22 0.35 0.951.04

.037.041

1.75 .069   X 
24 0.20 0.900.99

.035.039

1.75 .069    X

!,!-#

!. -/02 /+!,/,

!, 

!,"



,,'

,, # ,, #  6#
50419
18 0.87 2.75 .108 2.40 .094 88.2 19.8
20 0.50 2.55 .100 2.40 .094 58.8 13.2
22 0.35 2.40 .094 2.40 .094 39.2 8.8
24 0.20 2.30 .091 2.40 .094 29.4 6.6

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.

▲-/!,:

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).

5
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.PullForcevalueMustexceedtheMinimumpullforcespecificationslisted.



5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.
7
+


8+
8



HandCrimpToolFor3.50(.138”)WiretoWireConnector,CrimpPin
Doc o:ATS638238700 ReleaseDate:071311 Page3of7
Revision:A RevisionDate:071311



+/!%








 


+

+/!9
(



!,!,-
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.




















+/!4
+




:;




+/!1







+/!'

HandCrimpToolFor3.50(.138”)WiretoWireConnector,CrimpPin
Doc o:ATS638238700 ReleaseDate:071311 Page4of7
Revision:A RevisionDate:071311
+/!&


<

 
%

ote: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.



!,

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.Press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.


+/!$




:;

:;


+/!)
7

+




+/!1


:;
 
+/!)

HandCrimpToolFor3.50(.138”)WiretoWireConnector,CrimpPin
Doc o:ATS638238700 ReleaseDate:071311 Page5of7
Revision:A RevisionDate:071311

 !"!

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.



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.

-!,-!<,-

Shouldthistooleverbecomestuckorjammedinapartiallyclosedposition,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.

02

08%
9=***2
+/!1*

8
+/!11

7
+ 7
+/!>

HandCrimpToolFor3.50(.138”)WiretoWireConnector,CrimpPin
Doc o:ATS638238700 ReleaseDate:071311 Page6of7
Revision:A RevisionDate:071311
+/!1'

:;
7







8

?"@/-!"0
+/!1'2
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.

!!A
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.

:MolexcrimpspecificationsarevalidonlywhenusedwithMolexterminalsandtooling.

5
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.

!
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Preload).
%Whenthehandtoolisnolongercapableofachievingminimumpullforce,itshouldbetakenoutofserviceand
replaced.

HandCrimpToolFor3.50(.138”)WiretoWireConnector,CrimpPin
Doc o:ATS638238700 ReleaseDate:071311 Page7of7
Revision:A RevisionDate:071311

8
'
+/!1%

1
%



,/,6! !"!/,6! -! :/A
REF 638238700 HandCrimpTool Figure13
1 638238775 LocatorAssembly 1
2 638100104 Spring,Return 1
3 638100105 Spring,Ratchet 1

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



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














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
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
http://www.molex.com

