Molex 63823-5200 User manual

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal

Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 1 of 7

R vision: A R vision Dat : 06-17-10

HAND CRIMP TOOL

Specification Sheet

Order No. 6 82 -5200

FEATURES

 A full cycl ratch ting hand tool nsur s compl t crimps

 Ergonomic soft grip handl s for comfortabl crimping

 A pr cision us r-fri ndly t rminal locator wir stop holds t rminals in th prop r crimping position

 Right and L ft hand d applications

 This tool is WHMA-IPCA620 Class 2 compliant as indicat d

 This tool is RoHS compliant, how v r RoHS compliant is not r quir d

SCOPE

Products: 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal, 16–20 AWG

Terminal Order No. Wire Size Insulation Diameter Strip Length

Terminal Series No.

Loose Piece

Reel AWG

mm² mm In. mm In.

50350 50350-9101 50350-9001

16-20

1.30-0.50

1.70-2.60

.067-.102

2.80-3.40

.110-.134

 Custom r to cut off t rminal from r l: 0.30mm (.012”) maximum Cut-off Tab.

DEFINITION OF TERMS

Th abov t rminal drawing is a g n ric t rminal r pr s ntation. It is not an imag of a t rminal list d in th scop .

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

TYPE 4D

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal

Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 2 of 7

R vision: A R vision Dat : 06-17-10

CONDITIONS:

Aft r crimping, th conductor profil s should m asur th following.

Conductor Crimp

Wire Size Height Width (Ref.)

Profile

Terminal Series No

AWG

mm2

mm In. mm In. 16

16 1.30 1.32-1.42

.052-.056

1.90 .075 X

18 0.80 1.09-1.19

.043-.047

1.90 .075 X

50350

20 0.50 0.99-1.09

.039-.043

1.80 .071 X

Insulation Crimp

Wire Size Max Height (Ref.)

Width (Ref.)

Pull Force

Minimum

Terminal Series No

AWG

mm2

mm In. mm In. N Lb.

16 1.30 3.20 .126 2.30 .091 127.4

28.6

18 0.80 3.00 .118 2.30 .091 88.2 19.8

50350

20 0.50 2.60 .102 2.20 .087 58.8 13.2

OPERATION

CAUTION: Install only Mol x t rminals list d abov with this tool. Do not crimp hard n d obj cts as damag can

occur to th tool or di .

Op n th tool by squ zing th handl s tog th r. At th nd of th closing strok , th ratch t m chanism will

r l as th handl s and th hand tool will spring op n. S Figur 1.

Crimping Terminals

1. S l ct th d sir d t rminal list d

from th pr c ding charts. Th n

install it in th prop r locator (S

chart abov and s Locator

Installation on pag 5).

2. Mak sur th c nt r of th locator is

in th down position. With th

locator attach d, push th locator

button on th back of th hand tool to

bring th locator forward through th

tooling. S Figur 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 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal

Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 3 of 7

R vision: A R vision Dat : 06-17-10

RELEASE

LOCATOR BUTTON

TERMINAL Figure

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. Whil holding in th locator button, load th t rminal into th prop r

n st op ning in th locator, bas d on th wir gaug or t rminal typ

markings on th hand tooling. S Figur 3.

4. R l as th locator button, allowing th locator to r turn to th

crimping position.

5. Clos th tool handl until th first ratch t position ngag s. S

Figur 4.

6. Ins rt th prop rly stripp d wir through th t rminal and against th

wir stop. S Figur 5.

7. Crimp th t rminal by squ zing th tool handl s until th ratch t

m chanism cycl has b n compl t d. R l as th handl s to op n

th jaws.

Not : Th tamp r proof ratch t action will not r l as th tool until it has b n fully clos d.

8. R mov th crimp d t rminal from th t rminal locator by pulling on th wir .

9. Visually insp ct th crimp d t rminal for prop r crimp location.

10. On som larg O.D. wir s, it may not b possibl to ins rt th wir with th tool partially clos d. Thos wir s

should b ins rt d with th hand tool in th op n position. Ins rt th wir abov th t rminal in th punch and

against th wir stop th n clos th tool. S Figur 6.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal

Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 4 of 7

R vision: A R vision Dat : 06-17-10

MATCH

UP MARKS

FRONT BACK

Figure 12

Note:

A crimp h ight chart is provid d with this manual as

R f r nc Only. Du to th wid rang of wir s,

strands, insulation diam t rs, and durom t rs

availabl , actual crimp h ight m asur m nts may

v ry slightly. An occasional, d structiv , pull forc

t st should b pr form d to ch ck hand tool crimp.

Pull Forc valu Must xc d th Minimum pull forc

sp cifications list d.

Locator Replacement

S th parts list on th last pag of this docum nt for th prop r locator ord r numb r. Follow th st ps b low to

r plac th locator.

1. Op n th crimp hand tool.

2. Squ z g ntly on th low r ar a shown

in Figur 7A with your thumb and ind x

fing r. Th low r tabs of th locator

should dis ngag from th hand tool.

3. Lift and pull away from th hand tool. Th

top locator hooks should slip out of th top

slots asily. S Figur 7A.

4. To r install th n w locator, mak sur th

hand tool is in th op n position.

5. Pr ss th r d ins rt down as far as it will

go as shown in Figur 7B.

6. Holding onto th low r part of th locator

with your thumb and ind x fing r, ins rt

th locator top hooks (2) into th hand tool

top slots.

7. Rotat th locator down and pr ss th

low r tabs into th two bottom slots of th

hand tool. To s cur th locator into

plac , th low r tabs must snap into plac

on th hand tool fram .

Right or Left Hand Operation

This hand tool has an add d f atur that can b

conv rt d from a right hand d application to a l ft

hand d application. It is n c ssary to r v rs th

tooling along with th locator if using th l ft hand d

application. Follow th st ps b low:

1. Th locator must b r mov d b for r v rsing th

tooling.

2. R mov th M3 BHCS which is holding th upp r 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 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal

Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 5 of 7

R vision: A R vision Dat : 06-17-10

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

3. Flip th upp r tooling to th opposit sid and r plac th M3 BHCS Mak sur th small markings on th

front and back of th hand tool

fram match up and ar on th

outsid of th hand tool fram .

S Figur 8 and 9.

4. Do th sam thing with th low r

tooling and tight n th M3

scr ws. B sur th small

markings lin up.

5. R install th locator by following

th Instructions in th locator

r plac m nt s ction.

Maintenance

It is r comm nd d that ach op rator

of th tool b mad awar of, and r sponsibl for, th following maint nanc st ps:

1. R mov dust, moistur , and oth r contaminants with a cl an brush, or soft, lint fr cloth.

2. Do not us any abrasiv mat rials that could damag th tool.

3. Mak c rtain all pins; pivot points and b aring surfac s ar prot ct d with a thin coat of high quality machin

oil. Do not oil xc ssiv ly. Th tool was ngin r d for durability but lik any oth r quipm nt it n ds

cl aning and lubrication for a maximum s rvic lif of troubl fr crimping. Light oil (such as 30 w ight

automotiv oil) us d at th oil points,

v ry 5,000 crimps or 3 months, will

significantly nhanc th tool lif .

4. Wip xc ss oil from hand tool,

particularly from crimping ar a. Oil

transf rr d from th crimping ar a

onto c rtain t rminations may aff ct

th l ctrical charact ristics of an

application.

5. Wh n tool is not in us , k p th

handl s clos d to pr v nt obj cts from

b coming lodg d in th crimping di s,

and stor th tool in a cl an, dry ar a.

Miscrimps or Jams

Should this tool v r b com stuck or

jamm d in a partially clos d position, Do Not forc th handl s op n or clos d. Th tool will op n asily by

pr ssing up on th ratch t r l as l v r in th movabl handl . S Figur 11

How to Adjust Tool Preload

(See Figure 12)

This hand tool is factory pr s t to 25-45 LBS. pr load. It may b n c ssary ov r th lif of th tool to adjust tool

handl pr load forc . List d b low ar th st ps r quir d to adjust th crimping forc of th hand tool to obtain

prop r crimp conditions:

RATCHET RELEASE

LEVER

Figure 11

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY MONTHS OR

5,000 CRIMPS)

Figure 10

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal

Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 6 of 7

R vision: A R vision Dat : 06-17-10

1. Hold th hand tool in th palm of your hand as shown in Figur 12. Using th ind x fing r squ z th link

towards th top of th hand tool fram . This will r l as th pr load adjustm nt wh l.

2. Rotat th s tting wh l count r-clockwis (CCW) to incr as handl forc . Th numb rs will display high r.

To d cr as handl forc , rotat th s tting wh l clockwis (CW).

3. R l as th link to lock th s tting wh l in plac .

4. Ch ck th crimp sp cifications or conduct a pull t st aft r tool handl pr load forc is adjust d.

Warranty

This tool is for l ctrical t rminal crimping purpos s only. This tool is mad of th b st quality mat rials. All vital

compon nts ar long lif t st d. All tools ar warrant d to b fr of manufacturing d f cts for a p riod of 30

days. Should such a d f ct occur, w will r pair or xchang th tool fr of charg . This r pair or xchang will

not b applicabl to alt r d, misus d, or damag d tools. This tool is d sign d for hand us only. Any clamping,

fixturing, or us of handl xt nsions voids this warranty.

CAUTION: Mol x crimp sp cifications ar valid only wh n us d with Mol x t rminals and tooling.

CAUTIONS:

1. Manually pow r d hand tools ar int nd d for low volum or fi ld r pair. This tool is NOT int nd d for

production us . R p titiv us of this tool should b avoid d.

2. Insulat d rubb r handl s ar not prot ction against l ctrical shock.

3. W ar y prot ction at all tim s.

4. Us only th Mol x t rminals sp cifi d for crimping with this tool.

Certification

Mol x do s not c rtify or r -c rtify hand tools but rath r suppli s th following guid lin s for custom rs to r -c rtify

hand tools.

% This tool is qualifi d to pull forc only. To r -c rtify, crimp a t rminal to a wir , which has b n stripp d

12.7mm (1/2”) long, so th r is no crimping of th insulation. Pull th t rminal and wir at a rat no fast r than

25mm (1.00”) p r minut . S th Mol x w b sit for th Quality Crimp Handbook for mor information on pull

t sting.

% If th tool do s not m t minimum pull forc valu s, handl pr load should b incr as d and th pull t st

r run, (S How to Adjust Pr load).

% Wh n th hand tool is no long r capabl of achi ving minimum pull forc , it should b tak n out of s rvic and

r plac d.

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal

Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 7 of 7

R vision: A R vision Dat : 06-17-10

RATCHET

RELEASE LEVER

Figure 1

PARTS LIST

Item Number Order Number Description Quantity

REF 63823-5200 Hand Crimp Tool Figur 13

1 63823-5275 Locator Ass mbly (R d) 1

2 63810-0104 Spring, R turn 1

3 63810-0105 Spring, Ratch t 1

http://www.mol x.com

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