Molex MV-396 User guide

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

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

In.

35922

8011

35922

9002

0.80

0.50

3.00

.118x

3.00

3.50

.118

.138



Customer to cut off terminal from reel: 0.

20mm

(.00

”) maximum Cut

off Tab.

DEFINITION OF TERMS

TYPE 4D

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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

In.

35922

0.80

1.10

1.20

.043

.047

1.90

1.95

.074

.077

0.50

1.00

1.10

.039

.043

1.90

1.95

.074

.077

Terminal

Series No.

Wire Size

Insulation Crimp

Pull Force

Minimum

Hei ht (Ref.)

Width (Ref.)

AWG

In.

Lb.

35922

2.90

3.00

.114

.118

3.15

.124

88.2

19.8

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

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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

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Fi ure 4

FIRST RATCHET

POSITION

OPEN

POSITION

TERMINAL

Fi ure 6

WIRE

WIRE STOP

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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

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

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

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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

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

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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.

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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

TCHET

RELEASE LEVER

Fi ure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

638

Hand Crimp Tool

Figur

e 13

638

Locator Assembly

63810

0104

pring, Return

63810

0105

pring, Ratchet

http://www.molex.com

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