hand crimp tool for mv-396? wire-to-board crimp ter minals doc no: ats-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 t wisting seam wire hand crimp tool application tooling specification sheet order no. 63823-5900 features a full cycle ratcheting hand tool ensures complete crimps ergonomic soft grip handles for comfortable crimpin g a precision user-friendly terminal locator wire sto p holds terminals in the proper crimping position right and left handed applications this tool is ipc/whma a-620 class 2 compliant as in dicated this tool is rohs compliant, however rohs compliant is not required scope products : mv-396? 3.96 (.156) pitch wire-to-board crimp te rminals, 18-20 awg. terminal series no. terminal order no. wire size insulation diameter maximum strip length reel awg mm2 mm in. mm in. 35922 35922 - 8011 35922 - 9002 18 - 20 0.80 - 0.50 3.00 .118x 3.00 - 3.50 .118 - .138 customer to cut off terminal from reel: 0. 20mm (.00 8 ) maximum cut - off tab. definition of terms type 4d
hand crimp tool for mv-396? wire-to-board crimp ter minals doc no: ats-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 terminals 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 C compliant). while the insulation punch profile may appear lopsided, this is a normal condition for t his tool. see figure to the right. crimp specifications after crimping, the crimped terminals should measure as follows: terminal series no. wire size conductor crimp profile height (ref .) width (ref.) awg mm 2 mm in. mm in. 18 2 0 35922 18 0.80 1.10 - 1.20 .043 - .047 1.90 - 1.95 .074 - .077 x 20 0.50 1.00 - 1.10 .039 - .043 1.90 - 1.95 .074 - .077 x terminal series no. wire size insulation crimp pull force minimum height (ref.) width (ref.) awg mm 2 mm in. mm in. n lb. 35922 18 0. 80 2.90 - 3.00 .114 - .118 3.15 .124 88.2 19.8 20 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. a t the end of the closing stroke, the ratchet mechan ism will release the handles and the hand tool will spring o pen. see figure 1. locator in down postion push on the locator button figure 2 squeeze handles together handle will spring open figure 1 overlap insulation crimp overlap form geometry anvil punch wire
hand crimp tool for mv-396? wire-to-board crimp ter minals doc no: ats-638235900 release date: 08-26-10 uncontrolled copy page 3 of 7 revision: c revision date: 08-24-12 terminal figure 3 locator pushed thru tooling terminal release locator button locator button pushed in pre - stripped wire terminal figure 5 terminal wire against the wire stop wire wire stop is part of the locator 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 loca tor button on the back of the hand tool to bring the locator f orward through the tooling. see figure 2. 3. while holding the locator button in, load the termi nal into the proper nest opening in the locator bas ed on the wire gauge or terminal type markings on the hand to oling. 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 posit ion engages. see figure 4. 6. insert the properly stripped wire through the termi nal and against the wire stop. see figure 5. 7. crimp the terminal by squeezing the tool handles un til the ratchet mechanism cycle has been completed. release the ha ndles to open the jaws. note: the tamper proof ratchet action will not rele ase the tool until it has been fully closed. 8. remove the crimped terminal from the terminal locat or by pulling on the wire. 9. visually inspect the crimped terminal for proper cr imp location. 10. on some large o.d. wires, it may not be possible to insert the wire with the tool partially closed. those wires s hould be inserted with the hand tool in the open position. insert the wire above the terminal in the punch and against the wir e stop then close the tool. see figure 6. partiall y close handle tooling partially closed figure 4 first ratchet position open position terminal figure 6 wire wire stop
hand crimp tool for mv-396? wire-to-board crimp ter minals doc no: ats-638235900 release date: 08-26-10 uncontrolled copy page 4 of 7 revision: c revision date: 08-24-12 figure 8 push on handle jaws open pull open tooling tooling m3 bhcs match up marks front back figure 9 locator replacement 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 you r 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. right 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 to oling. 2. remove the m3 bhcs which is holding the upper tooli ng. 3. flip the upper tooling to the opposite side and rep lace 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 fi gure 8 and 9. 4. do the same thing with the lower tooling and tighte n 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 figure 7b squeeze here squeeze here locator figure 7a top hooks top slots of handtool lower tabs
hand crimp tool for mv-396? wire-to-board crimp ter minals doc no: ats-638235900 release date: 08-26-10 uncontrolled copy page 5 of 7 revision: c revision date: 08-24-12 figure 12 squeeze the link in the handle hold the hand tool in positi n 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 sur faces are protected with a thin coat of high quality machine oil. do not oi l excessively. the tool was engineered for durability but like any other eq uipment 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 signif icantly enhance the tool life. 4. wipe excess oil from hand tool, particularly from c rimping area. oil transferred from the crimping ar ea onto certain terminations may affect the electrical char acteristics of an application. 5. when tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimpi ng dies, and store the tool in a clean, dry area. miscrimps or jams should this tool ever become stuck or jammed in a p artially 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. how to adjust tool preload (see figure 12) this hand tool is factory preset to 25-45 lbs. prel oad. it may be necessary over the life of the tool to adjust tool handle pre load 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 te st after tool handle preload force is adjusted. lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 10 ratchet release lever figure 11
hand crimp tool for mv-396? wire-to-board crimp ter minals doc no: ats-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 purpo ses only. this tool is made of the best quality ma terials. all vital components are long life tested. all tools are war ranted to be free of manufacturing defects for a pe riod of 30 days. should such a defect occur, we will repair o r exchange the tool free of charge. this repair or exchange will not be applicable to altered, misused, or damaged t ools. this tool is designed for hand use only. an y clamping, fixturing, or use of handle extensions voids this w arranty. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling. cautions: 1. manually powered hand tools are intended for low vo lume 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 custo mers to re-certify hand tools. % this tool is qualified to pull force only. to re-c ertify, 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 n o faster than 25mm (1.00) per minute. see the molex web site fo r the quality crimp handbook for more information o n pull testing. % if the tool does not meet minimum pull force values , handle preload should be increased and the pull t est rerun, (see how to adjust preload). % when the hand tool is no longer capable of achievin g minimum pull force, it should be taken out of ser vice and replaced.
hand crimp tool for mv-396? wire-to-board crimp ter minals doc no: ats-638235900 release date: 08-26-10 uncontrolled copy page 7 of 7 revision: c revision date: 08-24-12 ra tchet release lever 2 figure 13 1 3 parts list item number order number description quantity ref 638 23 - 5 9 00 hand crimp tool figur e 13 1 638 23 - 59 75 locator assembly 1 2 63810 - 0104 spring, return 1 3 63810 - 0105 spring, ratchet 1 http://www.molex.com
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