Molex 63816-0200 User manual

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals

Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 1 of 6

Revision: B Revision Date: 10-13-10

TYPE 4A

Application Tooling

Specification Sheet

Modular Cri p Head

Order No. 63823-5370

Hand Cri p Tool

Order No. 63823-5300

FEATURES

% 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

% odular 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 63813-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).

SCOPE

Products: 3.96mm (.156”) Pitch Wire-to-Wire and 6.50mm (.256”) Pitch Wire-to-Board Crimp Terminals,

22-26 AWG.

Ter inal

Series

Ter inal Order No. Wire Size  Insulation Dia eter Wire Strip Length

Reel For only AWG 2 In. In.

50598 50598-8100

22 0.35 1.50-1.90 .059-.075

2.70-3.30 .106-.130

24 0.20 1.25-1.60 .049-.063

26 0.12 1.25-1.60 .049-.063

50600 50600-8100

22 0.35 1.50-1.90 .059-.075

24 0.20 1.25-1.60 .049-.063

26 0.12 1.25-1.60 .049-.063

Customer to cut off terminal from reel: 0.25mm (.010”) maximum Cut-off Tab.

 See crimp specification for the individual Insulation Diameter.

DEFINITION OF TERMS

This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

COND.CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals

Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 2 of 6

Revision: B Revision Date: 10-13-10

Figure 2

WIRE

TERMINAL

LOCATOR INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR ANVIL

CONDUCTOR

PUNCH

WIRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Figure 1

▲Insulation Cri p 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. See figure to the right.

(Some tools with multiple crimp pockets may not have

the “overlap” profile on all pockets).

CRIMP SPECIFICATIONS:

After crimping, the crimp profiles should measure the following.

Ter inal

Series No

Wire Size Conductor Cri p Insulation Cri p Pull Force

Mini u Profile

Height (Ref.) Width (Ref.)

Height (Ref.)

Width (Ref.)

AWG

In. M In. In. In. N Lb. AWG 22

AWG 24

AWG 26

50598

22 0.35

0.87-0.92

.034-.036

1.60 .063 2.30 .091 2.20 .087 39.23

8.82

24 0.20

0.80-0.85

.031-.034

1.60 .063 2.15 .085 2.20 .087 29.42

6.61

26 0.12

0.76-0.81

.030-.032

1.60 .063 2.00 .079 2.20 .087 14.71

3.31

50600

22 0.35

0.87-0.92

.034-.036

1.60 .063 2.30 .091 2.20 .087 39.23

8.82

24 0.20

0.80-0.85

.031-.034

1.60 .063 2.15 .085 2.20 .087 29.42

6.61

26 0.12

0.76-0.81

.030-.032

1.60 .063 2.00 .079 2.20 .087 14.71

3.31

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.

Cri ping Ter inals

1. Lift the wire stop blade up.

2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.

3. Bring down the wire stop blade.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals

Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 3 of 6

Revision: B Revision Date: 10-13-10

4. Slide the pre-stripped wire into the wire stop blade. See Figure 1. Be sure to hold the wire in place until the

terminal is fully crimped. See Figure 2.

5. Close the tool until the ratchet releases, the tool handles will then spring open.

6. Lift the wire stop blade up if it is still in down position.

7. Carefully remove the crimped terminal.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

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. ake 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.

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.

Miscri ps or Ja s

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 6.

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. anually 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 olex terminals specified for crimping with this tool.

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals

Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 4 of 6

Revision: B Revision Date: 10-13-10

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, however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding and insulation types may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. olex does not repair hand tools (see warranty above). 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.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to olex Quality Crimping

Handbook 63800-0029 for additional information on crimping and crimp testing.

6. olex does not certify crimp hand tools.

CAUTION: olex crimp specifications are valid only when used with olex terminals and tooling.

Applications for the Modular Cri p Head

WARNING: NEVER operate, service, install, or adjust this odular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper anual or Specification Sheet.

See Chart below for the correct anual 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.

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals

Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 5 of 6

Revision: B Revision Date: 10-13-10

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

OCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

The chart below shows all applications for this odular Crimp Head.

Modular Cri p Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63823-5370

63816-0000

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

63816-0050

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

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adapter 5

Applications for the Modular Cri p Head

Hand Cri p Tool Battery Powered Tool Air Powered Tool

Figure 3 Figure 4 Figure 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals

Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 6 of 6

Revision: B Revision Date: 10-13-10

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 6

M4 X 14

LONG BHCS

PARTS LIST

Hand Cri p Tool 63823-5300

Ite

Order Nu ber

Description Quantity

1 63823-5370 odular Crimp Head 1 (Ref)

2 63816-0050 Hand Crimp Frame (Long)

1 (Ref)

3 63823-5375 Locator 1

4 63816-0001 Locking Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

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