molex PremiumGrade Series User manual

Hand Crimp Tool for MV-396™ Wire-to-Board Crimp Terminals
Doc No: AT -638235900 Release Date: 08-26-10 UNCONTROLLED COPY Page 1 of 7
Revision: C Revision Date: 08-24-12
INSULATION CRIMP
▲SEE NOTE
BRUSH
STRIP LENGTH
BELL MOUTH
CUT
-
OFF
TAB
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP HEIGHT
T
WISTING
SEAM
WIRE
HAND CRIMP
TOOL
Application Toolin
Specification Sheet Order No. 63823-5900
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 IPC/WHMA A-620 Class 2 compliant as indicated
 This tool is RoH compliant, however RoH compliant is not required
SCOPE
Products: MV-396™ 3.96 (.156”) Pitch Wire-to-Board Crimp Terminals, 18-20 AWG.
Terminal
Series No.
Terminal Order No. Wire Size
Insulation Diameter
Maximum Strip Len th



Reel
AWG
mm²
mm
In.
mm
In.
35922
35922
-
8011
35922
-
9002
18
-
20
0.80
-
0.50
3.00
.118x
3.00
-
3.50
.118
-
.138

Customer to cut off terminal from reel: 0.
20mm
(.00
8
”) maximum Cut
-
off Tab.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool for MV-396™ Wire-to-Board Crimp Terminals
Doc No: AT -638235900 Release Date: 08-26-10 UNCONTROLLED COPY Page 2 of 7
Revision: C Revision Date: 08-24-12
▲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. ee figure to the right.
CRIMP SPECIFICATIONS
After crimping, the crimped terminals should
measure as follows:
Terminal
Series No.
Wire Size
Conductor Crimp
Profile
Hei ht (Ref
.)
Width (Ref.)
AWG
mm
2
mm
In.
mm
In.
18
2
0
35922
18
0.80
1.10
-
1.20
.043
-
.047
1.90
-
1.95
.074
-
.077
X
20
0.50
1.00
-
1.10
.039
-
.043
1.90
-
1.95
.074
-
.077
X
Terminal
Series No.
Wire Size
Insulation Crimp
Pull Force
Minimum
Hei ht (Ref.)
Width (Ref.)
AWG
mm
2
mm
In.
mm
In.
N
Lb.
35922
18
0.
80
2.90
-
3.00
.114
-
.118
3.15
.124
88.2
19.8
20
0.50
2.90
-
3.00
.114
-
.118
2.95
.116
58.8
13.2
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.


 Tool Qualification Notes:
1. Pull Force should be measured with no
influence from the insulation crimp.
2. The above specifications are guidelines to an
optimum crimp.
Note:
A crimp height chart is provided with this manual
as Reference Only. Due to the wide range of
wires, strands, insulation diameters, and
durometer 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 specification.
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. ee Figure 1.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Fi ure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Fi ure 1
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for MV-396™ Wire-to-Board Crimp Terminals
Doc No: AT -638235900 Release Date: 08-26-10 UNCONTROLLED COPY Page 3 of 7
Revision: C Revision Date: 08-24-12
TERMINAL Fi ure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
PRE
-
STRIPPED
WIRE
TERMINAL
Fi ure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
Crimpin Terminals
1. elect 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. ee 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. ee 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. ee Figure 4.
6. Insert the properly stripped wire through the terminal and against the wire
stop. ee 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.
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. ee Figure 6.
PARTIALL
Y
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Fi ure 4
FIRST RATCHET
POSITION
OPEN
POSITION
TERMINAL
Fi ure 6
WIRE
WIRE STOP

Hand Crimp Tool for MV-396™ Wire-to-Board Crimp Terminals
Doc No: AT -638235900 Release Date: 08-26-10 UNCONTROLLED COPY Page 4 of 7
Revision: C Revision Date: 08-24-12
Fi ure
8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Fi ure 9
Locator Replacement
ee 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. queeze 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. ee 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.
Ri ht 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 BHC which is holding the upper tooling.
3. Flip the upper tooling to the opposite side and replace the M3 BHC . 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. ee 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.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Fi ure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Fi ure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS

Hand Crimp Tool for MV-396™ Wire-to-Board Crimp Terminals
Doc No: AT -638235900 Release Date: 08-26-10 UNCONTROLLED COPY Page 5 of 7
Revision: C Revision Date: 08-24-12
Fi ure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN PO ITI
N
SETTING
WHEEL
RATCHET
RELEASE LEVER
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
hould 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. ee Figure 11.
How to Adjust Tool Preload (See Fi ure 12)
This hand tool is factory preset to 25-45 LB . 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Fi ure 10
RATCHET RELEASE
LEVER
Fi ure 11

Hand Crimp Tool for MV-396™ Wire-to-Board Crimp Terminals
Doc No: AT -638235900 Release Date: 08-26-10 UNCONTROLLED COPY Page 6 of 7
Revision: C Revision Date: 08-24-12
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. hould 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. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. ee 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, ( ee 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 MV-396™ Wire-to-Board Crimp Terminals
Doc No: AT -638235900 Release Date: 08-26-10 UNCONTROLLED COPY Page 7 of 7
Revision: C Revision Date: 08-24-12
RA
TCHET
RELEASE LEVER
2
Fi ure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
638
23
-
5
9
00
Hand Crimp Tool
Figur
e 13
1
638
23
-
59
75
Locator Assembly
1
2
63810
-
0104
pring, Return
1
3
63810
-
0105
pring, Ratchet
1
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