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Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638236800 - HANDTOOL CRIMP 2.5MM BOARDIN PIN 
Contact us: sales@integrated-circuit.com Website: www.integrated-circuit.com

Hand Crimp Tool For 

2.50mm (.098") Board-In Connector, Mini. Crimp Pin

 

Doc No: ATS-638236800 

Release Date: 10-25-10

 

UNCONTROLLED COPY

 

Page 4 of 7 

Revision: A 

Revision Date: 10-25-10 

Figure 8 

PUSH ON 

HANDLE 

 

PULL OPEN 

TOOLING 

TOOLING 

M3 BHCS 

 

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.  See Figure 6. 

 

 
 

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 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. 

 

TERMINAL 

Figure 6

 

WIRE 

WIRE STOP 

SQUEEZE 

HERE 

SQUEEZE 

HERE 

LOCATOR 

Figure 7A 

TOP HOOKS 

TOP SLOTS OF 

HANDTOOL 

LOWER TABS 

Figure 1 

HANDLE WILL 
SPRING OPEN 

SQUEEZE 
HANDLES 

Figure 7B 

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Summary of Contents for 63823-6800

Page 1: ...ed Excellent Integrated System Limited Stocking Distributor Stocking Distributor Click to view price real time Inventory Delivery Lifecycle Information Click to view price real time Inventory Delivery Lifecycle Information Molex Connector Corporation Molex Connector Corporation 0638236800 0638236800 For any questions you can email us directly For any questions you can email us directly sales integ...

Page 2: ...ecision 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 Terminal Order No Wire Size Insulation Diameter Strip Length IPC WHMA...

Page 3: ...m the insulation crimp 2 The above specifications are guidelines to an optimum crimp 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 S...

Page 4: ...ition 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 4 Release the locator button allowing the locator to return to the cri...

Page 5: ...close the tool See Figure 6 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 to...

Page 6: ...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...

Page 7: ...usted 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 dama...

Page 8: ...ard In Connector Mini Crimp Pin Doc No ATS 638236800 Release Date 10 25 10 UNCONTROLLED COPY Page 7 of 7 Revision A Revision Date 10 25 10 RATCHET RELEASE LEVER 2 Figure 13 1 3 PARTS LIST Item Number Order Number Description Quantity REF 63823 6800 Hand Crimp Tool Figure 13 1 63823 6875 Locator Assembly 1 2 63810 0104 Spring Return 1 3 63810 0105 Spring Ratchet 1 http www molex com Powered by TCPD...

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