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

In.

98897

98897-1109

0.35

1.25-1.40

.049-.055

4.30-4.70

.169-.185

98897-1129

1.40

2.20-2.40

.087-.094

1.50

2.10-2.30

.083-.091

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

In.

Degree

98897

0.40-0.80

.016-.032

0.20-1.00

.008-.039

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

In.

98897

0.35

0.92-0.98

.036-.039

1.55-1.65

.061-.065

1.40

1.31-1.41

.051-.055

2.15-2.35

.085-.093

1.50

1.33-1.43

.052-.056

2.15-2.35

.085-.093

2.00

1.40-1.50

.055-.059

2.15-2.35

.085-.093

Terminal

Series No.

Wire Size

Insulation Crimp

Pull Force Minimum

Height

Width Maximum

Wire Style

mm2/ AWG

In.

Lb.

98897

0.35

1.90-2.10

.075-.083

2.60

.102

13.5

1.40

2.44-2.64

.096-.104

3.25

.128

150

33.7

1.50

2.48-2.68

.098-.106

3.25

.128

155

34.8

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

---

63816-0270

Battery Power Tool (110 V)

63816-1950

Battery Power Crimp Adapter

63816-0280

Battery Power Tool (220 V)

63816-1950

Battery Power Crimp Adapter

63816-1900

Electric Crimp Machine

63816-1950

Battery Power Crimp Adapter

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)

Figure 6

M4 X FLAT

WASHER

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

---

Hand Crimp Frame

---

Modular Crimp Head

63819-8675

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

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.

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