Molex 50098 Series Manuel utilisateur

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382366HM Release Da e: 02-23-11 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Da e: 02-23-11

Application Tooling

Specification Sheet

Modular Crimp ead

Order No. 63823-6670

and Crimp Tool

Order No. 63823-6600

FEATURES

% A full cycle ra che ing hand ool ensures comple e crimps

% Ergonomically designed sof handles

% Precisely designed crimping profiles wi h simple con ac posi ioning

% Easy handling due o ou s anding force ra io

% Modular Crimp Head is removable and can be use in he Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adap er (Order No. 63816-0700).

% Can also be used in he Ba ery Powered Tool Order No.63816-0200 (110 V) or 63813-0250 (220 V),

accompanied by Ba ery Powered Crimp Adap er (Order No. 63816-0600).

SCOPE

Produc s: 4.00mm (.157”) Pi ch Board-In Crimp Terminal, 18-22 AWG, 0.85mm²; o 0.30mm² me ric wire.

Terminal

Series

Terminal Order No. Wire Size  Insulation Diameter Wire Strip Length

Reel Loose Wire Style mm² / AWG mm In. mm In.

50098 50098-8000 50098-8100

1.6-2.6 .063-.102 2.50-3.00 .098-.118

AVS 0.85

AVS 0.50

AVS 0.30

AV 0.85

AV 0.50

AV 0.75f

AV 0.50f

Cus omer o cu off erminal from reel: 0.20mm (.008”) maximum Cu -off Tab.

 See crimp specifica ion for he individual Insula ion Diame er.

TYPE 4A

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382366HM Release Da e: 02-23-11 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Da e: 02-23-11

DEFINITION OF TERMS

This illus ra ion is a generic erminal represen a ion and no an exac image of any erminal lis ed in he scope.

▲Insulation Crimp Note:

Due o he erminal’s insula ion grip design and/or

insula ion diame er range, his ool uses “overlap”

form geome ry in he insula ion punch. This produces

an overlap insula ion crimp (A620 – complian ).

While he insula ion punch profile may appear

“lopsided”, his is a normal condi ion for his ool. See

figure o he righ . (Some ools wi h mul iple crimp

pocke s may no have he “overlap” profile on all

pocke s).

CRIMP SPECIFICATIONS:

Af er crimping, he crimp profiles should measure he following.

Terminal

Series No.

Wire Size Conductor Crimp Profile

eight Width (Ref.)

Wire Style mm² / AWG mm In. mm In. 18awg

.75-.85mm

20awg

.50mm

22awg

.30mm

50098

18 1.12-1.22

.044-.048

1.65 .065 X

20 0.93-1.03

.037-.041

1.65 .065 X

22 0.87-0.92

.034-.036

1.65 .065 X

AVS 0.85 1.12-1.22

.044-.048

1.65 .065 X

AVS 0.50 0.96-1.06

.038-.042

1.65 .065 X

AVS 0.30 0.91-0.96

.036-.038

1.65 .065 X

AV 0.85 1.14-1.24

.045-.049

1.65 .065 X

AV 0.50 0.96-1.06

.038-.042

1.65 .065 X

AV 0.75f 1.07-1.17

.042-.046

1.65 .065 X

AV 0.50f 0.93-1.03

.037-.041

1.65 .065 X

INSULATION

CRIMP

▲SEE NOTE

BRUS

STRIP

LENGT

BELL MOUT

COND.CRIMP

EIG T

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNC

WIRE

Hand Crimp Tool for Board-In Crimp Terminals

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Revision: A Revision Da e: 02-23-11

WIRE

CONDUCTOR

PUNC

TERMINAL

WIRE STOP

BLADE

Figure 2

Terminal

Series No.

Wire Size Insulation Diameter







Insulation Crimp Pull Force

Minimum

eight (Ref.)

Width (Ref.)

Wire Style

mm² / AWG

mm In. mm In. mm In. N Lb.

50098

18 2.0-2.2 .079-.087 2.20 .087 2.75 .108

88.0

19.78

20 1.7-1.8 .067-.071 1.90 .075 2.75 .108

58.7

13.20

22 1.6-1.7 .063-.067 1.95 .077 2.30 .091

39.1

8.79

AVS 0.85 2.2-2.3 .087-.091 2.20 .087 2.75 .108

88.0

19.87

AVS 0.50 2.0-2.0 .079-.083 2.00 .079 2.75 .108

58.7

13.20

AVS 0.30 1.8-1.9 .071-.075 1.95 .077 2.30 .091

39.1

8.79

AV 0.85 2.4-2.6 .094-.102 2.20 .087 2.75 .108

88.0

19.78

AV 0.50 2.2-2.4 .087-.094 2.05 .081 2.75 .108

58.7

13.20

AV 0.75f 2.4-2.6 .094-.102 2.20 .087 2.75 .108

88.0

19.78

AV 0.50f 2.2-2.4 .087-.094 2.05 .081 2.75 .108

58.7

13.20

Tool Qualification Notes:

1. Pull Force should be measured wi h no influence from he

insula ion crimp.

2. The above specifica ions are guidelines o an op imum

crimp.

OPERATION

Open he ool by squeezing he handles oge her, a he end of

he closing s roke, he ra che mechanism will release he

handles, and he hand ool will spring open.

Crimping Terminals

1. Wi h he hand ool in he open posi ion, pivo he erminal

loca or open by pulling up on he loca or knob and lif he

wire s op blade up. See Figure 1.

2. Inser he erminal in o he correc profile un il he erminal is fully sea ed and s ops. Make sure he wire

s op blade is fully sea ed on he erminal behind he

conduc or grip sec ion.

3. Gen ly pivo he loca or closed.

4. Bring down he wire s op blade.

5. Slide he pre-s ripped wire in o he erminal; make sure o

aim he wire brush owards he ip poin on he wire s op

blade. See Figure 2. Align he wire so ha i is parallel and

si ing in o he erminal. Main ain a ligh and cons an

pressure on he wire ha is sea ed in he erminal a all

imes. (Do no le go of he wire.) Be sure o hold he wire

and erminal in place un il he erminal is fully crimped. See

Figure 3.

6. Close he ool un il he ra che releases.

7. Lif he wire s op blade up.

8. Carefully remove he crimped erminal.

Note: The amper proof ra che ac ion will no release he ool un il i has been fully closed.

TERMINAL

SEATED IN

LOCATOR

OPEN

Figure 1

AND TOOL

OPEN

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382366HM Release Da e: 02-23-11 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Da e: 02-23-11

INCORRECT

Figure 5

CORRECT INCORRECT

WIRE

CONDUCTOR

PUNC

WIRE STOP

BLADE

INSULATION

PUNC

LOCATOR

CONDUCTOR ANVIL

INSULATION

ANVIL

TERMINAL

Figure 3

Note: To main ain good brush con rol and a consis en bell mou h he crimping ins ruc ions mus be followed.

Terminal Locator Replacement/Change Over

This sec ion describes he procedure for changing loca ors.

Removal

1. Wi h he ool in he open posi ion, pivo he erminal

loca or ou ward.

2. Remove he M4 BHCS. See Figure 4.

Installation

1. Place he proper loca or, on he hand ool. Ins all he M4 BHCS. See Figure 4.

2. Tigh en he screw enough o hold he loca or. Make sure he loca or can s ill floa freely wi h hand pressure.

3. Inser he proper erminal fully in o he correc profile slo un il he erminal is fully sea ed and s ops. Then

gen ly pivo he loca or closed.

4. Wi h hand pressure, slowly slide he loca or o he correc posi ion. See Figure 5.

5. Gen ly pivo he loca or open wi hou dis urbing he loca ion.

6. Hold he loca or firmly in place and slowly igh en he M4 BHCS.

Maintenance

I is recommended ha each opera or of he ool be made aware of, and responsible for, he following

main enance s eps:

1. Remove dus , mois ure, and o her con aminan s wi h a clean brush, or sof , lin free clo h.

2. Do no use any abrasive ma erials ha could damage he ool.

M4 B CS

PIVOT LOCATOR

Figure 4

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382366HM Release Da e: 02-23-11 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Da e: 02-23-11

3. Make cer ain all pins; pivo poin s and bearing surfaces are pro ec ed wi h a hin coa of high quali y machine

oil. Do no oil excessively. The ool was engineered for durabili y bu like any o her equipmen i needs

cleaning and lubrica ion for a maximum service life of rouble free crimping. Ligh oil (such as 30 weigh

au omo ive oil) used a he oil poin s, every 5,000 crimps or 3 mon hs, will significan ly enhance he ool life.

4. Wipe excess oil from hand ool, par icularly from crimping area. Oil ransferred from he crimping area on o

cer ain ermina ions may affec he elec rical charac eris ics of an applica ion.

5. When ool is no in use, keep he handles closed o preven objec s from becoming lodged in he crimping dies,

and s ore he ool in a clean, dry area.

Miscrimps or Jams

Should his ool ever become s uck or jammed in a par ially closed posi ion, Do Not force he handles open or

closed. The ool will open easily by lif ing he ra che release lever. See Figure 6.

Warranty

This ool is for elec rical erminal crimping purposes only. This ool is made of he bes quali y ma erials. All vi al

componen s are long life es ed. All ools are warran ed o be free of manufac uring defec s for a period of 30

days. Should such a defec occur, we will repair or exchange he ool free of charge. This repair or exchange will

no be applicable o al ered, misused, or damaged ools. This ool is designed for hand use only. Any clamping,

fix uring, or use of handle ex ensions voids his warran y.

CAUTION: Repe i ive use of his ool should be avoided.

CAUTIONS:

1. Manually powered hand ools are in ended for low volume or field repair. This ool is NOT in ended for

produc ion use. Repe i ive use of his ool should be avoided.

2. Insula ed rubber handles are no pro ec ion agains elec rical shock.

3. Wear eye pro ec ion a all imes.

4. Use only he Molex erminals specified for crimping wi h his ool.

Notes:

1. This ool should only be used for he erminals and wire gauges specified on his shee .

2. This ool is no adjus able for crimp heigh , however crimp force is adjus able (See ins ruc ions above).

Varia ions in ools, erminals, wire s randing and insula ion ypes may affec crimp heigh .

3. This ool is in ended for s andard conduc or sizes. I may no give a good insula ion crimp suppor for all

insula ion sizes.

4. Molex does no repair hand ools (see warran y above). The replacemen par s lis ed are he only par s

available for repair. If he handles or crimp ooling is damaged or worn, a new ool mus be purchased.

5. Pull force should be used as he final cri eria for an accep able crimp. Pull force is measured wi h no

influence from he insula ion crimp. The insula ion should be s ripped long (1/2 in.) so he insula ion grips

on he erminal do no grip he wire insula ion or he conduc or. Refer o Molex Quali y Crimping

Handbook 63800-0029 for addi ional informa ion on crimping and crimp es ing.

6. Molex does no cer ify crimp hand ools.

CAUTION: Molex crimp specifica ions are valid only when used wi h Molex erminals and ooling.

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382366HM Release Da e: 02-23-11 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Da e: 02-23-11

MODULAR

CRIMP

EAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP EAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

Applications for the Modular Crimp ead

WARNING: NEVER opera e, service, ins all, or adjus his Modular Crimp Head wi hou proper ins ruc ion

and wi hou firs reading and unders anding he ins ruc ions in he proper Manual or Specifica ion Shee .

See Char below for he correc Manual or Specifica ion Shee .

WARNING: NEVER ins all ooling or service his ool while i is in o any power source. Disconnec he

power by unplugging or urn off he Ac ua or from i s power source.

CAUTION: Keep fingers away from he crimping area when opera ing his ool. I may cause severe injury.

CAUTION: Wear safe y glasses when opera ing or serving his ool.

The char below shows all applica ions for his Modular Crimp Head.

Modular Crimp ead

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description Figure No.

63823-6670

63816-0000

Hand Crimp Frame (Shor ) N/A N/A 3

63816-0050

Hand Crimp Frame (Long) N/A N/A 3

63816-0200

Ba ery Power Tool (110 V)

63816-0600

Ba ery Power Crimp Adap er

63816-0250

Ba ery Power Tool (220 V)

63816-0600

Ba ery Power Crimp Adap er

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adap er 5

Applications for the Modular Crimp ead

and Crimp Tool Battery Powered Tool Air Powered Tool

Figure 6 Figure 7 Figure 8

MODULAR

CRIMP

EAD

LOCKING

PINS

AND CRIMP

FRAME LONG

OR S ORT

Hand Crimp Tool for Board-In Crimp Terminals

Doc No: ATS-6382366HM Release Da e: 02-23-11 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Da e: 02-23-11

RATC ET

RELEASE LEVER

ANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 6mm

LONG B CS

PARTS LIST

and Crimp Tool 63823-6600

Item

Order Number

Description Quantity

1 63823-6670 Modular Crimp Head 1 (Ref)

2 63816-0050 Hand Crimp Frame (Shor )

1 (Ref)

3 63823-6675 Loca or 1

4 63816-0001 Locking Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

h p://www.molex.com

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