Molex 63823-4500 User guide

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 08-26-1

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT

OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAL

0.05

0.40 (REF)

SEAL POSITION

HAND CRIMP

TOOL

Appli ation Tooling

Spe ifi ation Sheet Order No. 63823-4500

FEATURES

 A full cycle ratcheting hand tool ensures complete crimps

 Ergonomic soft grip handles for comfortable crimping

 A precision 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 as indicated

 This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: CTX150 SWS Receptacle Terminals 0. 5-0.50 mm2.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diamet

Strip Length







Reel

Wire Type

mm²

In.

502 07 502 07- 001

502 07- 006

502 07- 101

502 07- 106

502 07- 401

502 07- 501

ZHID

0. 5 mm2

1.25

1.60

.049

.06

4.50-5.00

.177-.197

ZHIA

0. 5 mm2

1.25

1.60

.049

.06

ZHID

0.50 mm2

.40

1.60

.055

.06

4806 4806- 001

4806- 006

4806- 101

4806- 106

4806- 401

4806- 501

ZHID

0. 5 mm2

1.25

1.60

.049

.06

4.50-5.00

.177-.197

ZHIA

0. 5 mm2

1.25

1.60

.049

.06

ZHID

0.50 mm2

1.40

1.60

.055

.06



Customer to cut

off terminal from reel:

0. 0

.012

”) maximum Cut

off Tab.

DEFINITION OF TERMS

TYPE 4D

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 08-26-1

WIRE

INSULATION SEAL

0.05

0.40

Referen e

SEAL POSTION ON WIRE

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal Series No.

Bell mouth

Condu tor Brush

In.

502 07

0.20-0.55 .008-.022 0.20-1.20 .008-.047

4806

Terminal Series No. Bend up Bend down Twist Roll Seam

Seam shall not be

open and no wire allowed

out of the crimping area

Degree Max.

502 07

1 1 2

4806

After crimping, the crimp profiles should measure the following:

Terminal

Series No.

Wire Size

Condu tor

Insulation

Pull For e

Minimum

Crimp Height

Crimp Width

Max. Crimp Height Crimp Width

Wire Type

mm²

In.

Lb.

502 07

ZHID

. 5 mm2

0.81

0.87

.0 2

.0 4

1.65

.065

2.77

.10

109

.15

.11

.124

1 .5

ZHIA

0. 5 mm2

0.81

0.87

.0 2

.0 4

1.65

.065

2.72

.107

.00

.118

.12

1 .5

ZHID

0.50 mm2

0.80

0.90

.0 1

.0 5

1.65

.065

2.72

2.82

.107

111

.00

.20

.118

.126

18.0

4806

ZHID

0. 5 mm2

0.81

0.87

.0 2

.0 4

1.65

.065

2.77

.10

109

2.95

.15

.11

.124

1 .5

ZHIA

0. 5 mm2

0.81

0.87

.0 2

.0 4

1.65

.065

2.72

.107

.00

.118

.12

1 .5

ZHID

0.50 mm2

0.80

0.90

.0 1

.0 5

1.65

.065

2.82

.107

111

.00

.20

.118

.126

18.0

Terminal Series No.

Wire Size

Profile

Single Wire Seal

Wire Type

mm²

0.35 mm2

0.50 mm2

Order No.

Color

Seal Allowed Wire Ø

502 07

ZHID

. 5 mm2

See Note

ZHIA

. 5 mm2

ZHID

0.50 mm2

4806

ZHID

. 5 mm2

ZHIA

. 5 mm2

ZHID

0.50 mm2





Cable Seal Position On a Wire

(Before crimping)

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.

. See Product Application Specification AS-502 07-002 for

applicable Seal number, Color and Seal Allowed Wire Diameter.

Note:

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

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

occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must

exceed the Minimum pull force specifications listed.

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page of 7

Revision: A Revision Date: 08-26-1

Figure 4

TERMINAL

WIRE AGAINST

THEWIRE STOP

WIRE AND

SEAL POSITON

WIRE STOP IS

PART OF THE

LOCATOR

TERMINAL

WIRE AND SEAL

POSITIONED IN

LOWER PART OF

THE PUNCHES

OPERATION

CAUTION: Crimp only the Molex terminals

listed in the scope for this tool. Do not crimp

hardened objects as damage can occur to

the tool frame and/or crimp dies.

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. See Figure 1.

Crimping Terminals

1. Select the desired terminal listed in the

preceding charts.

2. Make sure the center of the locator is in the

down position. 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.

. 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 .

4. Release the locator button, allowing the locator to return to the crimping position.

5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the

upper tooling, until the wire is against the wire stop. See Figure 4.

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

TERMINAL

Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

RELEASE LOCATOR

BUTTON

LOCATOR

BUTTON

PUSHED IN

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 08-26-1

Figure

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

6. Seal position should be under and inside the punches, keep this position while crimping.

7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release the handles to open the jaws.

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.

Lo ator Repla ement

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.

. 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.

TERMINAL

Figure 6

WIRE

WIRE STOP

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 08-26-1

MATCH

UP MARKS

FRONT

BACK

Figure 9

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.

Right or Left Hand Operation

This hand tool has an added feature that can be converted

from a right handed application to a left handed

application. It is necessary to reverse the tooling if using

the left handed application along with the locator. Follow

the steps below:

1. The locator must be removed before reversing the

tooling.

2. Remove the M BHCS which is holding the upper tooling.

. Flip the upper tooling to the opposite side and replace the M BHCS.

Make sure the small markings on the front and back of the hand tool

frame, match up and are on the outside of the hand tool frame. See Figure

8 and 9.

4. Do the same thing with the lower tooling and tighten the M screws. Be

sure the small markings line up.

5. Reinstall the locator by following the Instructions in the locator replacement

section.

Maintenan e

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.

. 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 0 weight

automotive oil) used at the oil points, every 5,000 crimps or 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.

Mis rimps 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 pressing up on the ratchet release lever in

the movable handle. See Figure 11.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

RATCHET RELEASE

LEVER

Figure 11

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 08-26-1

Figure 12

SQUEEZE

THE LINK

IN THE HANDLE

HOLD THE HAND

TOOL IN POSITIN

SETTING WHEEL

RATCHET

RELEASE LEVER

How to Adjust Tool Preload

(See Figure 12)

This hand tool is factory preset to 25-45 LBS.

preload. It may be necessary over the life of

the tool to adjust tool handle preload force.

Listed below are the steps required to adjust

the crimping force of the hand tool to obtain

proper crimp conditions:

1. Hold the hand tool in the palm of your

hand as shown in Figure 12. Using the

index finger squeeze the link towards the

top of the hand tool frame. This will release the preload adjustment wheel.

2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.

To decrease handle force rotate the setting wheel clockwise (CW).

. Release the link to lock the setting wheel in place.

4. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.

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 0

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: 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.

. Wear eye protection at all times.

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

Certifi ation

Molex does not certify or re-certify 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.

% If the tool does not meet minimum pull force values, handle preload should be increased and the pull test

rerun, (See How to Adjust Preload).

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

replaced.

Hand Crimp Tool For CTX150 SWS Receptacle Terminals

Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 08-26-1

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number

Order Number

Des ription

Quantity

REF

638

Hand Crimp Tool

Figure 13

6 8

Locator Assembly

6 810

0104

Spring, Return

6 810

0105

Spring, Ratchet

Visit our Web site at http://www.molex.com

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