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!

Tel: +86-755-8981 8866 Fax: +86-755-8427 6832

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.



++



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&



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*

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+/!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



http://www.molex.com



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