molex 98897 User manual

Hand Crimp Tool: for NSCC 1.5 Receptacle Terminals
Doc No: ATS-6381986HM Release Date: 10-09-09 UNCONTROLLED COPY Page 1 of 6
Revision: C Revision Date: 06-30-23
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
COND.CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM
TYPE 4A
Order Number
63819-8600
Application Tooling
Specification Sheet
FEATURES
A full cycle ratcheting hand tool ensures complete crimps.
Ergonomic soft grip handles for comfortable crimping.
Right- and left-handed applications.
Easy handling due to outstanding force ratio
A precision user-friendly terminal locator with wire stop that holds terminals in the proper crimping position.
Tooling can be installed in the 63816-1950 Power Crimp Adapter, which is installed into the 63816-0270 (110 V)
or 63816-0280 (220 V) Battery Powered Tools and the 63816-1900 Electric Crimp Machine.
This tool is RoHS compliant; however, RoHS compliance is not required.
SCOPE
Products: NSCC 1.5 Receptacle Terminals for 0.35, 1.40, 1.50, and 2.00mm2
Terminal
Series
Terminal Order No.
Wire Size
Insulation Diameter
Wire Strip Length
Reel Form only
Wire Style
mm2/ AWG
mm
In.
mm
In.
98897
98897-1109
IR
0.35
1.25-1.40
.049-.055
4.30-4.70
.169-.185
98897-1129
IR
1.40
2.20-2.40
.087-.094
ID
1.50
2.10-2.30
.083-.091
IR
2.00
2.50-2.70
.098-.106
Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.

Hand Crimp Tool: for NSCC 1.5 Receptacle Terminals
Doc No: ATS-6381986HM Release Date: 10-09-09 UNCONTROLLED COPY Page 2 of 6
Revision: C Revision Date: 06-30-23
CRIMP SPECIFICATIONS:
Terminal Series No.
Bell mouth
Conductor Brush
Bend up Bend Down
Twist Roll
mm
In.
mm
In.
Degree
Degree
98897
0.40-0.80
.016-.032
0.20-1.00
.008-.039
2
2
2
6
After crimping, the crimp profiles should measure the following (See notes below).
Terminal
Series No.
Wire Size
Conductor Crimp
Profile
Height
Width
0.35mm2
2.00mm2
1.40mm2
1.50mm2
Wire Style
mm2/ AWG
mm
In.
mm
In.
A
B
C
98897
IR
0.35
0.92-0.98
.036-.039
1.55-1.65
.061-.065
X
IR
1.40
1.31-1.41
.051-.055
2.15-2.35
.085-.093
X
ID
1.50
1.33-1.43
.052-.056
2.15-2.35
.085-.093
X
IR
2.00
1.40-1.50
.055-.059
2.15-2.35
.085-.093
X
Terminal
Series No.
Wire Size
Insulation Crimp
Pull Force Minimum
Height
Width Maximum
Wire Style
mm2/ AWG
mm
In.
mm
In.
N
Lb.
98897
IR
0.35
1.90-2.10
.075-.083
2.60
.102
60
13.5
IR
1.40
2.44-2.64
.096-.104
3.25
.128
150
33.7
ID
1.50
2.48-2.68
.098-.106
3.25
.128
155
34.8
IR
2.00
2.55-2.75
.100-.108
3.25
.128
195
43.8
Insulation crimp should meet IPC/WHMA-A-620.
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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
TERMINAL
PRE-
STRIPPED
WIRE
LOCATOR
Figure 1
WIRE STOP
BLADE

Hand Crimp Tool: for NSCC 1.5 Receptacle Terminals
Doc No: ATS-6381986HM Release Date: 10-09-09 UNCONTROLLED COPY Page 3 of 6
Revision: C Revision Date: 06-30-23
TOOL QUALIFICATION NOTES
1. (Ref) means that the dimension provided is approximate because of the wide range of wires, conductor
stranding, insulation diameter and insulation hardness.
2. An occasional conductor crimp height measurement should be performed, and it should be used as the final
criterion for an acceptable crimp. It must lie between the minimum and maximum crimp height specification.
Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp
testing.
3. In addition, an occasional pull force test may be performed. It must exceed the minimum pull force
specification. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip
the wire long enough so the terminal insulation grips do not contact the wire insulation.
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 on page 4). 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.
CAUTION: Crimp only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
CERTIFICATION
Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools or determine tool life:
When the hand tool is no longer capable of achieving minimum conductor crimp height, it should be taken out
of service and replaced.
The tool frame is very difficult to disassemble and reassemble. Customer repair is not recommended.

Hand Crimp Tool: for NSCC 1.5 Receptacle Terminals
Doc No: ATS-6381986HM Release Date: 10-09-09 UNCONTROLLED COPY Page 4 of 6
Revision: C Revision Date: 06-30-23
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 weights 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.
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.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
Figure 2
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
RETAINER
SPACER

Hand Crimp Tool: for NSCC 1.5 Receptacle Terminals
Doc No: ATS-6381986HM Release Date: 10-09-09 UNCONTROLLED COPY Page 5 of 6
Revision: C Revision Date: 06-30-23
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
APPLICATIONS FOR THE MODULAR CRIMP HEAD
The chart below shows all applications for this Modular Crimp Head:
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63819-8600
Hand Crimp Tool
---
---
3
63816-0270
Battery Power Tool (110 V)
63816-1950
Battery Power Crimp Adapter
4
63816-0280
Battery Power Tool (220 V)
63816-1950
Battery Power Crimp Adapter
4
63816-1900
Electric Crimp Machine
63816-1950
Battery Power Crimp Adapter
5
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
Electric Crimp Machine
Figure 3
Figure 4
Figure 5
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.
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME
ELECTRIC
CRIMP
MACHINE
INSTALL BATTERY
POWERED ADAPTER WITH
CRIMP HEAD HERE

Hand Crimp Tool: for NSCC 1.5 Receptacle Terminals
Doc No: ATS-6381986HM Release Date: 10-09-09 UNCONTROLLED COPY Page 6 of 6
Revision: C Revision Date: 06-30-23
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
M4 X FLAT
WASHER
2
5
1
M4 X 14mm
LONG BHCS
PARTS LIST
Hand Crimp Tool 63819-8600
Item
Order Number
Description
Quantity
REF
63819-8600
Hand Crimp Tool
Figure 6
1
---
Hand Crimp Frame
1
2
---
Modular Crimp Head
1
3
63819-8675
Locator
1
4
63816-0001
Locking Pin
2
5
63600-0525
Handle Spring
1
6
63600-0520
Crimping Spring
2
Application Tooling Support
E-Mail: [email protected]
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective
owners.