Hand Crimp Tool for Board-In Crimp Terminals
Modular Crimp Head
Order No. 63827-8470
FEATURES
Application Tooling
Specification Sheet
TYPE 4A
Hand Crimp Tool
Order No. 63827-8400
A full cycle ratcheting hand tool ensures complete crimps
Ergonomically designed soft handles
Precisely designed crimping profiles with simple contact positioning
Easy handling due to outstanding force ratio
Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: Board-In Crimp Terminals, 22-26 AWG.
Terminal Series No.
90198
Terminal Order No.
90198-0001
Wire Size
AWG mm²
22-26
NA
Insulation
Diameter (Max.)
mm
In.
1.52
.060
►Strip
Length
mm
In.
1.70-2.10
.067-.083
Terminal will accommodate the following wire specification:
22 AWG-Solid Wire or Fused Wire
24-26 AWG Solid Wire, Fused Wire or Stranded Wire
To
achieve optimum IPC-A620 Class 2 insulation crimps, use this insulation OD range:
22 AWG: 1.45-1.52 mm, 24 AWG: 1.02-1.15 mm, 26 AWG: 0.90-1.05 mm
►Strip
Length
Check the insulation to ensure that there has been a nice clean cut. Wires with damaged insulation should not be
used. See Figure 1.
ACCEPT
REJECT
Insulation
Whiskers
STRIP
LENGTH
Split
Cut
Figure 1
Burred or Charred
Doc No: ATS-6382784HM
Revision: A
Release Date: 07-22-15
Revision Date: 07-22-15
UNCONTROLLED COPY
Page 1 of 6
Hand Crimp Tool for Board-In Crimp Terminals
DEFINITION OF TERMS
INSULATION
CRIMP
22 AWG: 1.23-1.30 mm
24-26 AWG: 1.17-1.25 mm
Diameter PC Board Hole
B
WIRE
B
CONDUCTOR
CRIMP
Figure 2
B
Section B-B
1.57
0.20 mm
Thick PC Board
CRIMP SPECIFICATIONS
After crimping, the conductor profiles should measure the following (See Figure 2).
Terminal Series No.
90198
Wire Size
AWG
22
24
26
Wire Size
AWG mm
2
22
NA
24
NA
26
NA
mm
2
NA
NA
NA
“A” Crimp Height (Ref.)
mm
0.89
0.79
0.74
In
.035
.031
.029
“B” Diagonal Dim.
Maximum
mm
In.
1.19
.047
1.14
.045
1.14
.045
♦Pull
Force
Minimum
N
Lb.
35.6 8.0
22.2 5.0
13.3 3.0
Terminal Series No.
90198
Insulation Crimp Height (Ref.)
mm
In.
1.65
.065
1.55
.061
1.50
.059
Insulation Crimp Width (Ref.) Profile
mm
In.
A B C
1.75
.069
X
1.55
.061
X
1.55
.061
X
♦
The crimp on this terminal is not an electrical crimp; the final soldering
operation is the electrical connection. This minimum pull force is what
should be expected when pulling the terminal with both insulation and
conductor crimped.
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.
“A”
“B”
“CRIMP PROFILE”
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. Variations in tools, terminals, wire stranding, and insulation types
may affect crimp height.
3. 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.
4. Pull force should be used as the final criteria for an acceptable crimp. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
5. Molex does not certify crimp hand tools.
Doc No: ATS-6382784HM
Revision: A
Release Date: 07-22-15
Revision Date: 07-22-15
UNCONTROLLED COPY
Page 2 of 6
Hand Crimp Tool for Board-In Crimp Terminals
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.
Preparing Terminals for Crimping
Figure 3
The terminals must be cut from the reel as shown. See Figure 3. The carrier strip hole is used to assist in loading
the terminal in position over the crimp anvils. The carrier strip will help maintain terminal position during crimping
and can be broken off after the crimp is complete.
Crimping Terminals
1. Load the terminal with carrier strip into the proper crimp profile. Make sure the carrier strip pilot hole fits over the
positioning pin.
2. Place the properly stripped wire into the correct profile and above the terminal. Pull the wire up; make sure all the
wire strands are captured inside the insulation stop/slot. Push the wire into the tool until the end of the insulation
contacts the insulation stop. See Figures 4 and 5.
3. While holding the wire with one hand, slowly squeeze the tool handles together to close the tool jaws until the
ratchet mechanism releases. At this point the handles can be released and will spring open.
4. Remove the crimped terminal and inspect for acceptable crimp attributes.
Note:
The tamper proof ratchet action will not release the tool until it has been fully closed.
INSULATION
PUNCH
INSULATION
STOP
CONDUCTOR
PUNCH
LOCATOR
POSITIONING
PIN
Figure 4
WIRE
RM
TERMINAL
NAL
LOCATOR
TERMINAL
CARRIER STRIP
CONDUCTOR
ANVIL
Maintenance
Figure 5
INSULATION ANVIL
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.
Doc No: ATS-6382784HM
Revision: A
Release Date: 07-22-15
Revision Date: 07-22-15
UNCONTROLLED COPY
Page 3 of 6
Hand Crimp Tool for Board-In Crimp Terminals
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 9.
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.
Applications for the Modular Crimp Head
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.
The chart below shows all applications for this Modular Crimp Head.
Doc No: ATS-6382784HM
Revision: A
Release Date: 07-22-15
Revision Date: 07-22-15
UNCONTROLLED COPY
Page 4 of 6
Hand Crimp Tool for Board-In Crimp Terminals
Modular Crimp Head
Order No.
Tool
Tool
Adapter
Adapter
Figure
Order no.
Description
Order No.
Description
No.
63816-0000 Hand Crimp Frame (Short)
N/A
N/A
6
63816-0050 Hand Crimp Frame (Long)
N/A
N/A
6
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter
7
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter
7
63816-0100
Air Power Tool
63816-0700
Air Power Crimp Adapter
8
63827-8470
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
BATTERY
POWERED
TOOL
Air Powered Tool
LOCKING
PINS
MODULAR
CRIMP
HEAD
LOCKING
PINS
LOCKING
PINS
MODULAR
CRIMP HEAD
AIR POWER
CRIMP
ADAPTER
LOCKING PINS
HAND CRIMP
FRAME LONG
OR SHORT
AIR
POWER
TOOL
LOCKING
PINS
Figure 6
Figure 7
Figure 8
Doc No: ATS-6382784HM
Revision: A
Release Date: 07-22-15
Revision Date: 07-22-15
UNCONTROLLED COPY
Page 5 of 6
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