Molex 63823-6470 User manual

Hand Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11

UNCONTROLLED COPY

Page 1 of 8

Revision: C Revision Date: 01-03-12

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

BEND

TWISTING

ROLLING

BEND

DOWN

WIRE

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63823-6470

Hand Crimp Tool

Ord r No. 63823-6400

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: PV Solar Pin and Socket Crimp Terminals, 10-1 AWG (6.0-2.5mm²)

T rminal

S ri s No.

T rminal Ord r No. Wir Siz and Typ Insulation Diam t r (r f) Strip L ngth

Loos R l only AWG mm² mm In. mm In.

130196 130196-0310

130196-031 10-12 6.00- .00

7.8 .31 7.00-10.00

.276-.39

130196-0313

130196-0315 1 2.50 6.7 .26 7.00-10.00

.276-.39

130197 130197-0325

130197-03 6 10-12 6.00- .00

7.8 .31 7.00-10.00

.276-.39

130197-0336

130197-03 7 1 2.50 6.7 .26 7.00-10.00

.276-.39

93302 93302-0006 93302-000 10-12 6.00- .00

7.8 .31 7.00-10.00

.276-.39

93302-0005 93302-0003 1 2.50 6.7 .26 7.00-10.00

.276-.39

93303 93303-0005 93303-0003 10-12 6.00- .00

7.8 .31 7.00-10.00

.276-.39

93303-0006 93303-000 1 2.50 6.7 .26 7.00-10.00

.276-.39

Customer to cut off terminal from reel: 0.50mm (.020”) 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.

TYPE 4C

Hand Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 2 of 8

Revision: C Revision Date: 01-03-12

CONDITIONS:

T rminal S ri s No. Wir Siz B ll mouth Cut-off Tab Maximum Conductor Brush

AWG mm² mm In. mm In. mm In.

130196 and 93302 10-1 6.00-2.50 0.20-1.50 .008-.059 0.50 .020 1.00-3.00 .039-.118

130197 and 93303 10-1 6.00-2.50 0.20-1.50 .008-.059 0.50 .020 1.00-3.00 .039-.118

T rminal S ri s No. Wir Siz B nd up B nd down Twist Roll Punch Width (R f)

S am

Seam shall not be open

and no wire allowed out

of the crimping area

Conductor

AWG mm2 D gr D gr mm In

130196 and 93302 10-12 6.00- .00 3 3 8 3.90 .15

1 2.50 3 3 8 2.90 .11

130197 and 93303 10-12 6.00- .00 3 3 8 3.90 .15

1 2.50 3 3 8 2.90 .11

After crimping, the conductor profile should measure the following.

T rminal S ri s No. Wir Siz Conductor Crimp H ight Pull Forc Minimum

AWG mm2 mm In. N Lb.

130196 and 93302

10 6.00 2.10-2.20 .083-.087 356.0 80.0

12 .00 2.00-2.10 .079-.083 312.0 70.0

1 2.50 1.60-1.70 .063-.067 223.0 50.0

130197 and 93303

10 6.00 2.10-2.20 .083-.087 356.0 80.0

12 .00 2.00-2.10 .079-.083 312.0 70.0

1 2.50 1.60-1.70 .063-.067 223.0 50.0

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 and stranding,

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:

Anvil and Punch Installation

1. Insert the Anvil into the bottom slots of the nest. Install the M x 10 long BHCS and tighten in place.

2. Insert the Punch into the top slots of the nest. Install the M x 18 long BHCS and tighten in place. See Figure

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 Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 3 of 8

Revision: C Revision Date: 01-03-12

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figur 2

ANVIL

POWER CRIMP

HEAD

Figur

PUNCH

M4 X 10mm LONG

BHCS

M4 X 18mm LONG

BHCS

SWING OPEN

TERMINAL

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.

2. Swing the existing 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. Turn the Locator Lock Latch down to unlock. See

Figure 3.

Figur 3

LATCH LOCKED

LATCH UNLOCKED

Hand Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page of 8

Revision: C Revision Date: 01-03-12

Figur 6

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

HANDLE

OPEN

LOCATOR

CLOSED

Figur 5

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

3. Swing the terminal locator away from the crimp tool shown in Figure . Some terminals with large conductor

grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be

loaded into the locator in the closed/crimp position. See Figure 5.

. Press down on the wire stop on the locator as shown in Figure1. Insert the proper terminal into the proper nest

opening. Make sure when choosing the nest opening, it will correspond with the 10, 12 or 1 profile on the hand

tool.

5. Return the locator to its original position.

6. Turn the Locator Lock Latch up to lock. Make

sure that the terminal is visually centered over

the punch.

7. Insert the proper wire over the terminal.

8. Gently touch the wire stop with the end of the

wire. See Figure 6 and 7.

9. Crimp the terminal by squeezing the tool handles

until the ratchet mechanism cycle has been

completed. Release handles to open the jaws.

10. Remove the crimped terminal from the terminal

locator by pressing down on the wire stop and

gently pulling on the wire.

11. Visually inspect the crimped terminal for proper

crimp location.

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

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 proper crimp location.

Figur 7

WIRE

CONDUCTOR ANVIL

LOCATOR

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

Hand Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 5 of 8

Revision: C Revision Date: 01-03-12

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 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 8A

or 8B 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 11)

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 11.

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.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 8A

Figur 8B

Hand Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 6 of 8

Revision: C Revision Date: 01-03-12

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.

63823-6 70

63810-1000

Hand Crimp Frame (Long) N/A N/A 9

63816-0200

Battery Power Tool (110 V)

63816-0300 Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300 Power Crimp Head

Applications for th Tool Kit

Hand Crimp Tool Batt ry Pow r d Tool

Figur 9 Figur 10

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 connected to any power source. Make sure

the power is disconnected.

CAUTION: To prevent injury, keep fingers away from the crimping area when operating this tool.

CAUTION: Wear safety glasses when operating or servicing this tool.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Hand Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 7 of 8

Revision: C Revision Date: 01-03-12

RATCHET

RELEASE SCREW

Figur 11

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 Frame (Long)

2 63823-6 70 Tool Kit with Locator 1

3 63823-6 75 Locator (only) REF

Hand Tool for PV Solar Pin and Socket Crimp Terminals

Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 8 of 8

Revision: C Revision Date: 01-03-12

Figur 12

M4 by 8mm Long

BHCS

M4 by 18mm Long

BHCS

M4 by 10mm 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

63823-6 70 63823-6 70 Tool Kit 1

http://www.molex.com

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