Molex 63823-5100 User guide

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal

Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 11-23-11

TYPE 4D

HAND CRIMP

TOOL

Application Tooling

Specification Sheet Or er No. 63823-5100

FEATURES

 full cycle ratcheting hand tool ensures complete crimps

 Ergonomic soft grip handles for comfortable crimping

 precision user-friendly terminal locator wire stop holds terminals in the proper crimping position

 Right and Left handed applications

 This tool is WHM -IPC 620 Class 2 compliant as indicated

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

SCOPE

Products: 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal, 22-26 WG.

Terminal Series No.

Terminal Or er No. Wire Size Insulation Diameter Strip Length

Loose Piece

Reel AWG

mm² mm In. mm In.

50372 50372-8100 50372-8000

22-26

0.35-0.12

0.95-1.40

.037-.055

1.30-1.80

.051-.071

56161 56161-8181 56161-8081

22-26

0.35-0.12

1.05-1.40

.041-.055

1.30-1.80

.051-.071

 Customer to cut off terminal from reel: 0.15mm (.006”) maximum Cut-off Tab.

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the

scope.

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal

Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 11-23-11

CONDITIONS:

fter crimping, the conductor profiles should measure the following.

Terminal Series No

Wire Size Con uctor Crimp Profile

Height Wi th (Ref.)

AWG

mm2

mm In. mm In. 22

50372

56161

22 0.35 0.70-0.75

.027-.029

1.20 .047 X

24 0.20 0.62-0.67

.024-.026

1.20 .047 X

26 0.12 0.57-0.62

.022-.024

1.20 .047 X

Terminal Series No

Wire Size Insulation Crimp Pull Force

Minimum

Max Height (Ref.)

Wi th (Ref.)

AWG

mm2

mm In. mm In. N Lb.

50372

56161

22 0.35 1.30 .051 1.45 .057 39.2 8.8

24 0.20 1.10 .043 1.45 .057 29.4 6.6

26 0.12 1.00 .039 1.45 .057 19.6 4.4

OPERATION

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

occur to the tool or die.

Open the tool by squeezing the handles together. t 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

from the preceding charts. Then

install it in the proper locator (See

chart above and see Locator

Installation on page 5).

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.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal

Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 11-23-11

RELEASE

LOCATOR BUTTON

TERMINAL Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

PRE-STRIPPED

WIRE

TERMINAL

Figure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS

PART OF

THE LOCATOR

3. While holding in the locator button, 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

crimping position.

5. Close the tool handle until the first ratchet position engages. See

Figure 4.

6. Insert the properly stripped wire through the terminal and against the

wire stop. See Figure 5.

7. Crimp the terminal by squeezing the tool handles until the ratchet

mechanism cycle has bee n 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.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal

Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 11-23-11

MATCH

UP MARKS

FRONT

BACK

Figure 12

Note:

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. n occasional, destructive, pull force

test should be preformed to check hand tool crimp.

Pull Force value Must exceed the Minimum pull force

specifications listed.

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 7 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 7 .

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

locator 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 Han 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 along with the locator if using the left handed

application. Follow the steps below:

1. The locator must be removed before reversing the

tooling.

2. Remove the M3 BHCS which is holding the upper tooling.

TERMINAL

Figure 6

WIRE

WIRE STOP

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal

Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 11-23-11

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

3. Flip the upper tooling to the

opposite side and replace the M3

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 M3 screws.

Be sure the small markings line up.

5. Reinstall the locator by following

the Instructions in the locator

replacement section.

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. 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 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.

Miscrimps 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

RATCHET RELEASE

LEVER

Figure 11

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal

Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 11-23-11

How to A just Tool Preloa (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).

3. 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. ll vital

components are long life tested. ll 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. ny 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.

3. Wear eye protection at all times.

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

Certification

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 djust 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 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal

Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 11-23-11

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number Or er Number Description Quantity

REF 63823-5100 Hand Crimp Tool Figure 13

1 63823-5175 Locator ssembly (Red) 1

2 63810-0104 Spring, Return 1

3 63810-0105 Spring, Ratchet 1

http://www.molex.com

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