Molex 39-00-0039 Crimp Socket Contact User Manual

Introduction

This manual provides detailed instructions for the proper use and handling of the Molex 39-00-0039 Crimp Socket Contact. This component is designed for reliable electrical connections in various applications, accommodating 24-18 AWG wires. Adherence to these instructions ensures optimal performance and longevity of the contact.

Figure 1: Molex 39-00-0039 Crimp Socket Contact. This image displays a single Molex crimp socket contact, a small metallic component designed for electrical connections. It features a cylindrical barrel for wire insertion and crimping, and a rectangular mating interface with retention features. The contact is shown in a horizontal orientation against a white background.

Setup

Before beginning the crimping process, ensure you have the correct tools and materials:

• Molex 39-00-0039 Crimp Socket Contacts: Ensure contacts are free from damage or corrosion.
• Wire: 24-18 AWG (American Wire Gauge) stranded or solid wire, appropriate for your application.
• Wire Stripper: Calibrated for 24-18 AWG wires.
• Crimping Tool: A dedicated Molex crimping tool or a universal crimping tool with appropriate dies for Molex contacts is highly recommended for optimal crimp quality. Refer to the crimping tool's manual for specific die selection.
• Wire Housing (Optional): If the contact will be inserted into a connector housing, ensure it is compatible with Molex Mini-Fit Jr. series contacts.

Preparation Steps:

1. Inspect Contacts: Visually inspect each contact for any manufacturing defects or damage.
2. Prepare Wire: Using the wire stripper, carefully strip approximately 3-4 mm (0.12-0.16 inches) of insulation from the end of the wire. Ensure the wire strands are not cut or damaged during stripping. Twist the exposed strands lightly to keep them together.

Operating Instructions (Crimping)

Follow these steps to properly crimp the Molex 39-00-0039 contact onto a prepared wire:

1. Insert Contact into Tool: Open the crimping tool and place the Molex contact into the appropriate crimp cavity (die) for the wire gauge (24-18 AWG). Ensure the contact is seated correctly and held in place by the tool's locator. The insulation barrel should align with the larger crimp section, and the wire barrel with the smaller crimp section.
2. Insert Wire: Insert the stripped end of the wire into the wire barrel of the contact until the insulation butts against the insulation stop. Ensure all wire strands are within the wire barrel.
3. Crimp: Close the crimping tool handles firmly and completely until the ratchet mechanism releases (if applicable). This ensures a full and proper crimp.
4. Remove Crimped Contact: Open the tool and carefully remove the crimped contact.
5. Inspect Crimp: Visually inspect the crimp for quality.
   • The wire strands should be fully enclosed and compressed within the wire barrel.
   • The insulation should be captured by the insulation barrel, providing strain relief without being cut.
   • There should be no loose strands or sharp edges.
   • Perform a gentle pull test on the wire to ensure it is securely held by the contact.
6. Insert into Housing (if applicable): If using a connector housing, align the crimped contact with the correct cavity and push it in until you hear or feel a click, indicating the locking tangs have engaged. Gently pull on the wire to confirm it is locked in place.

Maintenance

Molex crimp contacts are designed for durability. Proper storage and handling are key to maintaining their integrity:

• Storage: Store contacts in their original packaging or in a clean, dry, and dust-free environment. Avoid exposure to extreme temperatures, humidity, or corrosive substances.
• Handling: Handle contacts by their body, avoiding contact with the mating surfaces to prevent contamination or damage.
• Crimping Tool Care: Regularly clean and lubricate your crimping tool according to its manufacturer's instructions to ensure consistent crimp quality.

Troubleshooting

If you encounter issues during the crimping or assembly process, consider the following:

• Poor Crimp Quality:
  • Cause: Incorrect crimping tool/die, improper wire stripping length, incorrect wire gauge, or incomplete crimp cycle.
  • Solution: Verify tool and die compatibility, ensure correct strip length (3-4mm), confirm wire gauge (24-18 AWG), and ensure the tool fully cycles.
• Wire Pull-Out:
  • Cause: Insufficient crimp force, wire not fully inserted into the wire barrel, or damaged wire strands.
  • Solution: Ensure the crimping tool fully cycles, verify wire insertion depth, and inspect wire for damage before stripping.
• Difficulty Inserting into Housing:
  • Cause: Deformed contact, bent locking tangs, or incorrect orientation.
  • Solution: Inspect the contact for deformation, ensure locking tangs are not bent, and verify correct orientation before insertion. Do not force the contact.

Specifications

Warranty and Support

For specific warranty information regarding the Molex 39-00-0039 Crimp Socket Contact, please refer to the official Molex website or contact your authorized Molex distributor. Warranty terms typically cover manufacturing defects.

For technical support, product inquiries, or assistance with specific applications, please visit the official Molex website or contact their customer service department. Ensure you have the product model number (39-00-0039) available when seeking support.

Note: This manual provides general guidance. Always refer to the latest product datasheets and application specifications provided by Molex for critical applications.