handcrimptoolfor 2.50mm(.098")boardinconnector,mini.crimppin docno:ats638236800 releasedate:102510 uncontrolled copy page1of7 revision:a revisiondate:102510 insulation crimp brush strip length bell mouth crimp height bend down bend up rolling conductor crimp twisting hand crimp tool application tooling specification sheet order no. 63823-6800 features afullcycleratchetinghandtoolensurescomplete crimps ergonomicsoftgriphandlesforcomfortablecrimpin g aprecisionuserfriendlyterminallocatorwiresto pholdsterminalsinthepropercrimpingposition rightandlefthandedapplications thistoolisipc/whmaa620class2compliant thistoolisrohscompliant,howeverrohscompliant isnotrequired scope products :2.5(.098)boardinconnector,minicrimppin,2 228awg. terminal series no. terminal order no. wire size insulation diameter strip length ipc/whma-a620 terminal loose piece reel awg mm2 mm in. mm in. mm in. 5394 08701044 08701043 2228 .35.08 1.201.50 .047.059 1.201.70 .047.067 2.102.70 .083.106 customertocutoffterminalfromreel:0.30mm(.01 2)maximumcutofftab. toachieveoptimumipca620class2insulationcrim ps,usethisinsulationodrange. overallinsulationodspecificationforterminal. definition of terms theaboveterminaldrawingisagenericterminalre presentation.itisnotanimageofaterminallis tedinthe scope. type 4d
handcrimptoolfor 2.50mm(.098")boardinconnector,mini.crimppin docno:ats638236800 releasedate:102510 uncontrolled copy page2of7 revision:a revisiondate:102510 conditions: aftercrimping,theconductorprofileshouldmeasur ethefollowing. terminal series no. wire size conductor profile crimp height crimp width (ref) awg mm 2 mm in. mm in. 22 24 26 28 5394 22 0.35 0.690.74 .027.029 1.25 .049 x 24 0.20 0.610.66 .024.026 1.25 .049 x 26 0.12 0.540.59 .021.023 1.25 .049 x 28 0.08 0.510.56 .020.022 1.25 .049 x terminal series no. wire size insulation (ref) pull force minimum crimp height crimp width awg mm 2 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 toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluence fromtheinsulationcrimp. 2. theabovespecificationsareguidelinestoanop timumcrimp. insulation crimp note : duetotheterminalsinsulationgripdesign and/orinsulationdiameterrange,thistool usesoverlapformgeometryinthe insulationpunch.thisproducesanoverlap insulationcrimp(a620Ccompliant).while theinsulationpunchprofilemayappear lopsided,thisisanormalconditionforthis tool.seefiguretotheright.(sometoolswith multiplecrimppocketsmaynothavethe overlapprofileonallpockets). note: acrimpheightchartisprovidedwiththis manualasreferenceonly. duetothewiderangeofwires,strands,insulati ondiameters,anddurometers available,actualcrimpheightmeasurementsmayver yslightly.anoccasional,destructive,pullforce testshouldbe performedtocheckhandtoolcrimp.pullforceval uemust exceedtheminimumpullforcespecificationsliste d. operation caution: installonlymolexterminalslistedabovewiththis tool.donotcrimphardenedobjectsasdamagecan occurtothetoolordie. openthetoolbysqueezingthehandlestogether.a ttheendoftheclosingstroke,theratchetmechan ismwill releasethehandlesandthehandtoolwillspringo pen.seefigure1. make sure center of locator overlap form geometry anvil punch wire
handcrimptoolfor 2.50mm(.098")boardinconnector,mini.crimppin docno:ats638236800 releasedate:102510 uncontrolled copy page3of7 revision:a revisiondate:102510 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. selectthedesiredterminallistedinthe precedingcharts. 2. makesurethecenterofthelocatorisinthe downposition.withthelocatorattached, pushthelocatorbuttononthebackofthe handtooltobringthelocatorforwardthrough thetooling.seefigure2. 3. whileholdingthelocatorbuttonin,loadthe terminalintothepropernestopeninginthe locatorbasedonthewiregaugeorterminal typemarkingsonthehandtooling.see figure3. 4. releasethelocatorbutton,allowingthelocatorto returntothecrimping position. 5. closethetoolhandleuntilthefirstratchetposit ionengages.seefigure 4. 6. inserttheproperlystrippedwirethroughthetermi nalandagainstthe wirestop.seefigure5. 7. crimptheterminalbysqueezingthetoolhandlesun tiltheratchet mechanismcyclehasbeencompleted.releasetheha ndlestoopenthe 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
handcrimptoolfor 2.50mm(.098")boardinconnector,mini.crimppin docno:ats638236800 releasedate:102510 uncontrolled copy page4of7 revision:a revisiondate:102510 figure 8 push on handle pull open tooling tooling m3 bhcs note:thetamperproofratchetactionwillnotrele asethetooluntilithasbeenfullyclosed. 8. removethecrimpedterminalfromtheterminal locatorbypullingonthewire. 9. visuallyinspectthecrimpedterminalforproper crimplocation. 10. onsomelargeo.d.wires,itmaynotbepossibleto insertthewirewiththetoolpartiallyclosed.th ose wiresshouldbeinsertedwiththehandtoolinthe openposition.insertthewireabovetheterminal in thepunchandagainstthewirestopthenclosethe tool.seefigure6. locator replacement seethepartslistonthelastpageofthisdocumen tfor theproperlocatorordernumber.followthesteps belowtoreplacethelocator. 1. openthecrimphandtool. 2. squeezegentlyonthelowerareashownin figure7awithyourthumbandindexfinger. thelowertabsofthelocatorshoulddisengage fromthehandtool. 3. liftandpullawayfromthehandtool.thetop locatorhooksshouldslipoutofthetopslots easily.seefigure7a. 4. toreinstallthenewlocator,makesurethehand toolisintheopenposition. 5. presstheredinsertdownasfarasitwillgoas showninfigure7b. 6. holdingontothelowerpartofthelocatorwithyou r thumbandindexfinger,insertthelocatorstop hooks(2)intothehandtooltopslots. 7. rotatethelocatordownandpressthelowertabs intothetwobottomslotsofthehandtool.to securethelocatorintoplace,thelowertabsmust snapintoplaceonthehandtoolframe. 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
handcrimptoolfor 2.50mm(.098")boardinconnector,mini.crimppin docno:ats638236800 releasedate:102510 uncontrolled copy page5of7 revision:a revisiondate:102510 right or left hand operation thishandtoolhasanaddedfeaturethatcanbe convertedfromarighthandedapplicationtoaleft handedapplication.itisnecessarytoreversethe toolingifusingthelefthandedapplicationalong withthe locator.followthestepsbelow: 1. thelocatormustberemovedbeforereversingthe tooling. 2. removethem3bhcswhichisholdingtheuppertooli ng. 3. fliptheuppertoolingtotheoppositesideandrep lacethem3bhcs. makesurethesmallmarkingsonthefrontandback ofthehandtool framematchupandareontheoutsideofthehandt oolframe.see figure8and9. 4. dothesamethingwiththelowertoolingandtighte nthem3screws.be surethesmallmarkingslineup. 5. reinstallthelocatorbyfollowingtheinstructions inthelocator replacementsection. maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,and responsiblefor,thefollowingmaintenancesteps: 1. removedust,moisture,andothercontaminantswith acleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. 3. makecertainallpins;pivotpointsandbearingsur facesareprotected withathincoatofhighqualitymachineoil.don otoilexcessively.the toolwasengineeredfordurabilitybutlikeanyoth erequipmentitneeds cleaningandlubricationforamaximumservicelife oftroublefree crimping.lightoil(suchas30weightautomotive oil)usedattheoil points,every5,000crimpsor3months,willsignif icantlyenhancethetool life. 4. wipeexcessoilfromhandtool,particularlyfromc rimpingarea.oil transferredfromthecrimpingareaontocertainter minationsmayaffect theelectricalcharacteristicsofanapplication. 5. whentoolisnotinuse,keepthehandlesclosedto preventobjectsfrombecominglodgedinthecrimpi ngdies, andstorethetoolinaclean,dryarea. miscrimps or jams shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, do not forcethehandlesopenor closed. thetoolwillopeneasilybypressingupontherat chetreleaseleverinthemovablehandle.seefigu re 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
handcrimptoolfor 2.50mm(.098")boardinconnector,mini.crimppin docno:ats638236800 releasedate:102510 uncontrolled copy page6of7 revision:a revisiondate:102510 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) thishandtoolisfactorypresetto2545 lbs.preload.itmaybenecessaryover thelifeofthetooltoadjusttoolhandle preloadforce.listedbelowarethesteps requiredtoadjustthecrimpingforceofthe handtooltoobtainpropercrimp conditions: 1. holdthehandtoolinthepalmofyour handasshowninfigure10.using theindexfingersqueezethelink towardsthetopofthehandtool frame.thiswillreleasethepreload adjustmentwheel. 2. rotatethesettingwheelcounterclockwise(ccw)to increasehandleforce.thenumberswilldisplayh igher. todecreasehandleforcerotatethesettingwheelc lockwise(cw). 3. releasethelinktolockthesettingwheelinplace . 4. checkthecrimpspecificationsorconductapullte staftertoolhandlepreloadforceisadjusted. warranty thistoolisforelectricalterminalcrimpingpurpo sesonly.thistoolismadeofthebestqualityma terials.allvital componentsarelonglifetested.alltoolsarewar rantedtobefreeofmanufacturingdefectsforape riodof30 days.shouldsuchadefectoccur,wewillrepairo rexchangethetoolfreeofcharge.thisrepairor exchangewill notbeapplicabletoaltered,misused,ordamagedt ools.thistoolisdesignedforhanduseonly.an yclamping, fixturing,oruseofhandleextensionsvoidsthisw arranty. caution :molexcrimpspecificationsarevalidonlywhenu sedwithmolexterminalsandtooling. cautions: 1. manuallypoweredhandtoolsareintendedforlowvo lumeorfieldrepair.thistoolis not intendedfor productionuse.repetitiveuseofthistoolshould beavoided. 2. insulatedrubberhandlesarenotprotectionagainst electricalshock. 3. weareyeprotectionatalltimes. 4. useonlythemolexterminalsspecifiedforcrimping withthistool. certification molexdoesnotcertifyorrecertifyhandtoolsbut rathersuppliesthefollowingguidelinesforcusto merstorecertify handtools. % thistoolisqualifiedtopullforceonly.seethe molexwebsiteforthequalitycrimphandbookfor more informationonpulltesting. % ifthetooldoesnotmeetminimumpullforcevalues ,handlepreloadshouldbeincreasedandthepullt est rerun,(seehowtoadjustpreload). % whenthehandtoolisnolongercapableofachievin gminimumpullforce,itshouldbetakenoutofser viceand replaced.
handcrimptoolfor 2.50mm(.098")boardinconnector,mini.crimppin docno:ats638236800 releasedate:102510 uncontrolled copy page7of7 revision:a revisiondate:102510 ratchet release lever 2 figure 13 1 3 parts list item number order number description quantity ref 638236800 handcrimptool figure13 1 638236875 locatorassembly 1 2 638100104 spring,return 1 3 638100105 spring,ratchet 1 http://www.molex.com
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