Molex 63823-4100 User manual

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 1 of 8

Revision: A Revision Date: 01-19-11

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT

OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAL

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63823-4170

Hand Crimp Tool

Ord r No. 63823-4100

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

 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is

installed into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.

 Many different Tool kits can be used with a single Battery Powered Tool.

 This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.

SCOPE

Products: CP 2.8 receptacle for 12 - 10 AWG type TXL wire and >3 - 5 mm2 type ID and IR wire with 2.80mm

(.110") CMC Wire Seal (See Note  )

T rminal S ri s No.

T rminal Ord r No

Wir Siz

and Typ

Insulation Diam t r

Strip

L ngth



Availabl in R l only

AWG

mm²

In.

6 32 6 32 -1019 6 32 -1119 12-10 TXL >3 – 5 Type ID & IR 3. – .0 .13 - .157 .90-5.10 .193-.201

6 32 -2019 6 32 -2119



Customer to cut off terminal from r

eel: 0.30mm (.012

”) maximum Cut

ff Tab.

Not : Terminal will accommodate the thin wall small insulation with the TXL type American wires and the ID or IR type metric wires.

 For TXL-12AWG wire uses Seal color GREY, For TXL-10AWG, mm2 and 5mm2 wires use Seal color BLUE.

DEFINITION OF TERMS

TYPE 4C

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 2 of 8

Revision: A Revision Date: 01-19-11

ANVILS

POWER

CRIMP

HEAD

Figur

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

CRIMP SPECIFICATION

T rminal S ri s No.

B ll Mouth

B nd up B nd down

Twist Roll

Conductor Brush

In.

D gr

In.

6 32

0.5

.020

0.2

0.6

.008

.02

S am:

Seam shall not be open and no wire allow

ed out of the crimping area.

After crimping, the conductor profiles should measure the following (See notes below).

T rminal

S ri s No.

Wir Siz

Conductor

Insulation

Pull Forc

Minimum Profil

Crimp H ight

(R f)

Crimp Width

(R f)

Crimp H ight

(R f)

rimp Width

(R f)

AWG

mm2

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

12 AWG

10AWG

6 32

3.31

2.00

2.10

.079

.083

3. 9

.137

5.05

–

5.35

.199

.21

5.06

.199

2.00

2.10

.079

.083

3. 9

.137

5.05

–

5.35

.199

.211

5.06

.199

320

1.9

5.26

2.10

2.20

.083

.087

3.50

.138

5.25

–

5. 5

.207

.215

5.07

.200

2.10

2.20

.083

.087

3.50

.138

5.25

–

5. 5

.207

.215

5.07

.200

360

80.9

Tool Qualification Not s:

1. Pull Force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

Not :

A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,

insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,

destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the

minimum pull force specifications listed.

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool or die.

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the

steps below:

Anvils and Punch s Installation

1. Insert the Anvils into the bottom slots of the nest. Install

the M x 10 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install

the M x 18 long BHCS and tighten in place. See

Figure 1.

Locator Installation and R moval

Follow the steps below to install or replace the locator. See

Figure 2.

To install th locator

1. Position the locator with the hole over the brass pivot shaft and snap it into place.

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 3 of 8

Revision: A Revision Date: 01-19-11

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figur

SWING OPEN

ERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

TERMINAL

IN PLACE

Figur 4

LOCATOR LATCH

IN OPEN POSITION

To r mov th locator

1. Open the crimp hand tool and unlock the locator latch.

2. Swing the locator open and away from the hand tool.

3. Firmly press down on the brass pivot shaft with your thumb, while pulling

the locator up. Slip the locator off the top of the brass pivot shaft.

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.

Crimping T rminals

1. Select the desired terminal listed in the preceding charts.

2. Unlock the locator latch and swing the terminal locator away from the crimp tool shown in Figure 3 and .

3. Press down on the wire stop on the locator as shown in

Figure . Insert the proper terminal into the proper

nest opening. Make sure when choosing the nest

opening, it will correspond with the correct profile on

the hand tool.

. Return the locator to closed position. Make sure the locator latch is in lock position. Insert the proper wire with

the seal over the terminal. Gently touch the wire stop with the end of the wire and align the seal with the grips

on the terminal. See Figure 5 and 6.

Figur 3

LATCH LOCKED

LATCH UNLOCKED

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page of 8

Revision: A Revision Date: 01-19-11

LOCATOR

Figur 6

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

SEAL

TERMINAL

PRE

TRIPPED

WIRE WITH SEAL

Figur 5

WIRE STOP

BLADE

5. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

6. Unlock the locator latch and swing the locator open.

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

7. Remove the crimped terminal from the

terminal locator by pressing down on the

wire stop and gently pulling on the wire.

8. Visually inspect the crimped terminal for an

acceptable crimp.

For th Batt ry Pow r Tool:

1. Cycle the Battery Power Tool to crimp the

terminal to the wire.

2. Remove the crimped terminal from the

terminal locator by pressing down on the

wire stop and gently pulling on the wire.

3. Visually inspect the crimped terminal for an

acceptable crimp.

Maint nanc

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 in the tool head are protected with a thin coat of high

quality machine oil. Do not oil excessively. This tool was engineered for durability, but like any fine piece of

equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. The use of

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 7A

Figur 7B

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 5 of 8

Revision: A Revision Date: 01-19-11

light oil, such as 30 weight automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life

and ensure a stable calibration. See Figure 7A or 7B for lubrication points.

. Store the tool in a clean and dry area when not in use.

Miscrimps or Jams for Crimp Hand Tools Only

(S Figur 10)

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 rotating the small slotted screw marked with an arrow. See Figure 10.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

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

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.

. Use only the Molex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

C rtification

Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for

customers to re-certify hand tools.

% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped

12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than

25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull

testing.

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

The chart below shows all applications for this Tool Kit.

Tool Kit

Ord r No.

Tool

Ord r no.

Tool

D scription

Pow r

H ad

Ord r No.

Adapt r

D scription Figur No.

63823- 170

6381

1050

Hand Crimp Frame (Short

)

N/A

6381

100

Hand Crimp Frame (Long)

N/A

63816

0200

Battery Power

Tool (110 V)

63816

0300

Power Crimp Head

63816

0250

Battery Power

Tool (220 V)

63816

0300

Power Crimp Head

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 6 of 8

Revision: A Revision Date: 01-19-11

Applications for th Tool Kit

Hand Crimp Tool

Batt r

y Pow r d Tool

Figur

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper

instruction and without first reading and understanding the instructions in the proper Manual or

Specification Sheet. See Chart above for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the

power is turned off.

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.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 7 of 8

Revision: A Revision Date: 01-19-11

RATCHET

RELEASE SCREW

Figur 10

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

It m Numb r

Ord r Numb r

D scription

Quantity

63810

1000

Hand Crimp Fr

ame (Long)

638

Tool Kit with

Locator

63823

175

Locator (only)

REF

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals

Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 8 of 8

Revision: A Revision Date: 01-19-11

Figur 11

Long

BHCS

Long

BHCS

Long

BHCS

POWER HEAD PARTS LIST

It m

Ord r No

Engin ring No.

D scription

Quantity

63816-0300 63816-0300 Power Crimp Head 1

63823- 170 63823- 170

Tool Kit with

Locator

http://www.molex.com

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