Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp Pin
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63823-6800
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
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.5 (.098”) Board-In Connector, Mini Crimp Pin, 22-28 AWG.
Terminal
Series No.
5394
Terminal Order No.
Loose Piece
08-70-1044
Reel
Wire Size
AWG
mm²
Insulation Diameter
IPC/WHMA-A620
Terminal
mm
In.
mm
In.
Strip Length
mm
In.
08-70-1043 22-28 .35-.08 1.20-1.50 .047-.059 1.20-1.70 .047-.067 2.10-2.70 .083-.106
Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.
To achieve optimum IPC-A620 Class 2 insulation crimps, use this insulation OD range.
Overall insulation OD specification for terminal.
DEFINITION OF TERMS
BEND UP
BRUSH
BELL MOUTH
ROLLING
CONDUCTOR
CRIMP
INSULATION
CRIMP
TWISTING
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Doc No: ATS-638236800
Revision: A
Release Date: 10-25-10
Revision Date: 10-25-10
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp Pin
CONDITIONS:
After crimping, the conductor profile should measure the following.
Terminal Series No.
5394
Wire Size
AWG
22
24
26
28
Terminal Series No.
5394
mm2
0.35
0.20
0.12
0.08
Conductor
Profile
Crimp Height
Crimp Width (Ref)
mm
In.
mm
In.
22 24 26 28
0.69-0.74 .027-.029
1.25
.049
X
0.61-0.66 .024-.026
1.25
.049
X
0.54-0.59 .021-.023
1.25
.049
X
0.51-0.56 .020-.022
1.25
.049
X
Wire Size
AWG
22
24
26
28
mm2
0.35
0.20
0.12
0.08
Insulation (Ref)
Pull Force Minimum
Crimp Height Crimp Width
mm
In.
mm
In.
N
Lb.
1.55 .061 1.85 .073
39.10
8.79
1.45 .057 1.85 .073
29.40
6.61
1.35 .053 1.85 .073
19.60
4.41
1.25 .049 1.85 .073
9.80
2.20
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.
▲Insulation Crimp Note:
OVERLAP FORM GEOMETRY
PUNCH
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).
MAKE SURE
CENTER OF
LOCATOR
WIRE
Note:
ANVIL
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.
OPERATION
CAUTION: 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.
Doc No: ATS-638236800
Revision: A
Release Date: 10-25-10
Revision Date: 10-25-10
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp Pin
Crimping Terminals
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.
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOGETHER
Figure 2
PUSH ON THE
LOCATOR BUTTON
Figure 1
LOCATOR
PUSHED THRU
TOOLING
RELEASE
LOCATOR BUTTON
LOCATOR
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Figure 3
TOOLING
PARTIALLY
CLOSED
TERMINAL
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.
WIRE AGAINST
THE WIRE STOP
TERMINAL
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 4
WIRE STOP IS PART OF
THE LOCATOR
PRE-STRIPPED
WIRE
Figure 5
WIRE
Doc No: ATS-638236800
Revision: A
Release Date: 10-25-10
Revision Date: 10-25-10
TERMINAL
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp Pin
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
WIRE
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.
WIRE STOP
Figure 6
TERMINAL
LOCATOR
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
Locator Replacement
Figure 1
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOP SLOTS OF
HANDTOOL
TOP HOOKS
Figure 7B
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.
LOWER TABS
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.
Doc No: ATS-638236800
Revision: A
Release Date: 10-25-10
Revision Date: 10-25-10
PULL OPEN
TOOLING
TOOLING
M3 BHCS
Figure 8
PUSH ON
HANDLE
UNCONTROLLED COPY
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Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp Pin
Right or Left Hand Operation
MATCH
UP MARKS
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:
Figure 9
FRONT
BACK
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
LUBRICATION POINTS
replacement section.
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Maintenance
It is recommended that each operator of the tool be made aware of, and
responsible for, the following maintenance steps:
Figure 10
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.
RATCHET RELEASE
LEVER
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
Figure 11
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 pressing up on the ratchet release lever in the movable handle. See Figure
11.
Doc No: ATS-638236800
Revision: A
Release Date: 10-25-10
Revision Date: 10-25-10
UNCONTROLLED COPY
Page 5 of 7
Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp Pin
How to Adjust Tool Preload (See
Figure 12)
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:
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
1. Hold the hand tool in the palm of your
hand as shown in Figure 10. Using
Figure 12
the index finger squeeze the link
SETTING
towards the top of the hand tool
WHEEL
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.
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: 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. 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.
Doc No: ATS-638236800
Revision: A
Release Date: 10-25-10
Revision Date: 10-25-10
UNCONTROLLED COPY
Page 6 of 7
Hand Crimp Tool For 2.50mm (.098") Board-In Connector, Mini. Crimp Pin
PARTS LIST
Item Number
REF
1
2
3
Order Number
63823-6800
63823-6875
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
3
http://www.molex.com
Doc No: ATS-638236800
Revision: A
Release Date: 10-25-10
Revision Date: 10-25-10
UNCONTROLLED COPY
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