Molex 63823-0400 User guide

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638230470 - MODULAR CRIMP HEAD

Excellent Integrated System Limited

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0638230470

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Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638230470 - MODULAR CRIMP HEAD

Hand Crimp Tool: for 2.80mm (.110") Pitch UCC2 Receptacle Terminal

Doc o: ATS-6382304HM Release Date: 12-15-07 UNCONTROLLED COPY Page 1 of 6

Revision: B Revision Date: 08-12-10

TYPE 4A

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT-OFF TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

INSULATION CRIMP

▲SEE NOTE

Applicatio Tooli g

Specificatio Sheet

Modular Crimp Head

Order No. 63823-0470

Ha d Crimp Tool

Order No. 63823-0400

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

% 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: 2.80mm (.110") Pitch UCC2 Receptacle Terminal, 0.35mm²; to 0.75mm² metric wire.

Termi al Series No.

Termi al Order No.

Wire Size I sulatio Diameter

Strip Le gth

Reel Form O ly

Wire Style

mm² / AWG

mm I . mm I .

98898 98898-1029

IR 0.35

1.25-1.90 .049-.075 4.50 .177

IR 0.50

IR 0.60

IR 0.35 + 0.35

IR 0.75

Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.

 IPC/WHMA-A-620 Class 2 only 1.25-1.90mm dia. (.049-.075”)

See crimp specification for the individual Insulation Diameter.

DEFINITION OF TERMS

2 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638230470 - MODULAR CRIMP HEAD

Hand Crimp Tool: for 2.80mm (.110") Pitch UCC2 Receptacle Terminal

Doc o: ATS-6382304HM Release Date: 12-15-07 UNCONTROLLED COPY Page 2 of 6

Revision: B Revision Date: 08-12-10

▲I sulatio 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 SPECIFICATIONS:

Termi al Series No. Bell mouth Co ductor Brush Be d up Be d Dow Twist Roll

mm I . mm I . Degree Degree

98898 0.05-1.00 .002-.039 0.20-1.00 .008-.039 2 2 6 2

After crimping, the crimp profiles should measure the following (See notes on page 4).

Termi al Series No.

Wire Size Co ductor Crimp Profile

Height Width

mm2 mm I . mm

I . A B C

98898

0.35 1.01-1.09

.040-.043

2.20

.087

0.50 1.06-1.14

.042-.045

2.20

.087

0.60 1.06-1.14

.042-.045

2.20

.087

0.35 + 0.35

1.06-1.14

.042-.045

2.20

.087

0.75 1.11-1.19

.044-.047

2.20

.087

Termi al

Series No.

Wire Size I sulatio Diameter







I sulatio Crimp Pull Force

Mi imum

Height Width Maximum

mm2 mm I . mm I . mm I . N Lb.

98898

0.35 1.25-1.40

.049-.055

2.15-2.35

.085-.093

2.60 .102 60.0

13.5

0.50 1.40-1.70

.055-.067

2.35-2.55

.093-.100

2.60 .102 70.0

15.7

0.60 1.60-1.80

.063-.071

2.35-2.55

.093-.100

2.60 .102 80.0

18.0

0.35 + 0.35

1.25-1.40

.049-.055

2.40-2.60

.095-.102

2.60 .102 60.0

13.5

0.75 1.70-1.90

.067-.078

2.55-2.75

.100-.108

2.60 .102 90.0

20.2

ΤΤ

Τ 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.

TERMINAL

PRE-

STRIPPED

WIRE

LOCATOR

Figure 1

WIRE STOP

BLADE

OVERLAP

INSULATION

IMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

3 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638230470 - MODULAR CRIMP HEAD

Hand Crimp Tool: for 2.80mm (.110") Pitch UCC2 Receptacle Terminal

Doc o: ATS-6382304HM Release Date: 12-15-07 UNCONTROLLED COPY Page 3 of 6

Revision: B Revision Date: 08-12-10

Crimpi g Termi als

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.

Mai te a ce

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 6.

Figure 2

CONDUCTOR

PUNCH

WIRE

LOCATOR

TERMINAL

INSULATION

PUNCH

INSULATION

ANVIL

CONDUCTOR

ANVIL

WIRE STOP

BLADE

RETAINER

SPACER

4 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638230470 - MODULAR CRIMP HEAD

Hand Crimp Tool: for 2.80mm (.110") Pitch UCC2 Receptacle Terminal

Doc o: ATS-6382304HM Release Date: 12-15-07 UNCONTROLLED COPY Page 4 of 6

Revision: B Revision Date: 08-12-10

Warra ty

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. 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.

5 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638230470 - MODULAR CRIMP HEAD

Hand Crimp Tool: for 2.80mm (.110") Pitch UCC2 Receptacle Terminal

Doc o: ATS-6382304HM Release Date: 12-15-07 UNCONTROLLED COPY Page 5 of 6

Revision: B Revision Date: 08-12-10

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

DULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

Applicatio s 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 o.

Tool

Descriptio

Adapter

Order No.

Adapter

Descriptio

Figure

No.

63823-0470

63816-0000

Hand Crimp Frame (Short) /A /A 3

63816-0050

Hand Crimp Frame (Long) /A /A 3

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adapter 5

Applicatio s for the Modular Crimp Head

Ha d Crimp Tool Battery Powered Tool Air Powered Tool

Figure 3 Figure 4 Figure 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

6 / 7

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638230470 - MODULAR CRIMP HEAD

Hand Crimp Tool: for 2.80mm (.110") Pitch UCC2 Receptacle Terminal

Doc o: ATS-6382304HM Release Date: 12-15-07 UNCONTROLLED COPY Page 6 of 6

Revision: B Revision Date: 08-12-10

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 6

M4 X FLAT

WASHER

M4 X 14mm

LONG BHCS

PARTS LIST

Ha d Crimp Tool 63823-0400

Item

Order Number

Descriptio Qua tity

1 63823-0470 Modular Crimp Head 1 (Ref)

2 63816-0050 Hand Crimp Frame (Long)

1 (Ref)

3 63823-0475 Locator 1

4 63816-0001 Locking Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

http://www.molex.com

7 / 7

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