Molex 63823-7570 User manual

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals

Doc o: ATS-6382375HM Release Date: 09-27-10 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 10-14-10

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

COND.CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

Applicatio Tooli g

Specificatio Sheet

Modular Crimp Head

Order No. 63823-7570

Ha d Crimp Tool

Order No. 63823-7500

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

% A-620 Class 3 compliant and RoHS compliant

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order o.63816-0100,

accompanied by Air Powered Crimp Adapter (Order o. 63816-0700).

% Can also be used in the Battery Powered Tool Order o.63816-0200 (110 V) or 63816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order o. 63816-0600).

SCOPE

Products: 2.50mm (.098”) Wire-to-Board Crimp Terminals, 22-28 AWG.

Termi al

Series No.

Termi al

Order No. Wire Size I sulatio Diameter Strip Le gth

●Reel AWG

mm² mm I . mm I .

50752 50752-8000

50752-8100

22-28

0.35-0.08

1.15-1.80 .045-.071

2.00-2.50

.078-.098

● Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.

See Conditions on page 2.

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 4A

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals

Doc o: ATS-6382375HM Release Date: 09-27-10 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 10-14-10

▲I sulatio Crimp Note:

Due to the terminal’s insulation grip design and/or

insulation diameter range, this tool uses “overlap” form

geometry in the insulation punch. This produces an

overlap insulation crimp (A620 – compliant). While the

insulation punch profile may appear “lopsided”, this is a

normal condition for this tool. See figure to the right.

(Some tools with multiple crimp pockets may not have

the “overlap” profile on all pockets).

CRIMP SPECIFICATIONS:

Termi al Series No. Bell mouth Co ductor Brush Be d up Be d Dow Twist Roll

mm I . mm I . Degree Degree

50752 0.05-0.40 .002-.016 0.00-0.60 .000-.023 3 3 3 6

After crimping, the crimp profiles should measure the following.

Termi al

Order No.

Wire Size

Co ductor Crimp I sulatio Crimp Pull Force

Mi imum 



Profile

Height (Ref) Width (Ref)

Height (Ref)

Width (Ref)

AWG

mm2

mm I . mm I . mm I . mm I . N Lb.

50752

22 0.35

0.84-0.89

.033-.035

1.20 .047 1.8 .071 1.80 .071 39.2

8.8 X

24 0.20

0.76-0.81

.030-.032

1.20 .047 1.8 .071 1.80 .071 29.4

6.6 X

26 0.12

0.71-0.76

.028-.030

1.20 .047 1.7 .067 1.80 .071 19.6

4.4 X

28 0.08

0.67-0.72

.026-.028

1.20 .047 1.7 .067 1.80 .071 9.8 2.2 X

To Achieve IPC-A-620 Class 3 Crimps, the following over-all wire insulation diameter ranges are recommended:

Profile 22: 1.50-1.65mm (.059-.065”)

Profile 24: 1.30-1.50mm (.051-.059”)

Profile 26: 1.20-1.40mm (.047-.055”)

Profile 28: 1.20-1.30mm (.047-.051”)

■Tool Qualificatio Notes:

1. Pull Force should be measured with no

influence from the insulation crimp.

2. The above specifications are guidelines

to an optimum crimp.

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.

1. With the hand tool in the open position, pivot

the terminal locator open by pulling up on

the locator knob and lift the wire stop blade

up. See Figure 1.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP BLADE

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals

Doc o: ATS-6382375HM Release Date: 09-27-10 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 10-14-10

WIRE

CONDUCTOR

PUNCH

TERMINAL

WIRE STOP

BLADE

Figure 2

WIRE

CONDUCTOR

PUNCH

WIRE STOP

BLADE INSULATION

PUNCH

LOCATOR

CONDUCTOR

ANVIL

INSULATION

ANVIL

TERMINAL

Figure 3

2. Insert the terminal into the correct profile until the terminal is fully seated and stops. Make sure the wire

stop blade is fully seated on the terminal behind the conductor grip section.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade.

5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush towards the tip point on the

wire stop blade. See Figure 2. Align the wire so that it is parallel and sitting into the terminal. Maintain a

light and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the

wire.) Be sure to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Lift the wire stop blade up.

8. Carefully remove the crimped terminal.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be

followed.

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

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

Termi al Locator Replaceme t/Cha ge Over

This section describes the procedure for changing locators.

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

I stallatio

1. Place the proper locator, (See Chart on page 2), on the hand tool.

Install the M4 BHCS. See Figure 4.

2. Tighten the screw enough to hold the locator. Make sure the

locator can still float freely with hand pressure. M4 BHCS

PIVOT LOCATOR

Figure 4

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals

Doc o: ATS-6382375HM Release Date: 09-27-10 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 10-14-10

INCORRECT

Figure 5

CORRECT INCORRECT

3. Insert the proper terminal fully into the correct profile slot

until the terminal is fully seated and stops. Then gently

pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct

position. See Figure 5.

5. Gently pivot the locator open without disturbing the

location.

6. Hold the locator firmly in place and slowly tighten the M4

BHCS.

Mai te a ce

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 lifting the ratchet release lever. See Figure 9.

Warra ty

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 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. Any clamping,

fixturing, or use of handle extensions voids this warranty.

CAUTION: Repetitive use of this tool should be avoided.

CAUTIONS:

1. Manually powered hand tools are intended for low volume or field repair. This tool is OT 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.

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals

Doc o: ATS-6382375HM Release Date: 09-27-10 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 10-14-10

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 63800-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

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

Applicatio s for the Modular Crimp Head

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

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

power by unplugging or turn off the Actuator from its power source.

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.

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals

Doc o: ATS-6382375HM Release Date: 09-27-10 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 10-14-10

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order o.

Tool

Descriptio

Adapter

Order No.

Adapter

Descriptio

Figure

No.

63823-7570

63816-0000

Hand Crimp Frame (Short) /A /A 6

63816-0050

Hand Crimp Frame (Long) /A /A 6

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adapter 8

Applicatio s for the Modular Crimp Head

Ha d Crimp Tool Battery Powered Tool Air Powered Tool

Figure 6 Figure 7 Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for 2.50mm (.098”) Wire-to-Board Crimp Terminals

Doc o: ATS-6382375HM Release Date: 09-27-10 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 10-14-10

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 8mm

LONG BHCS

PARTS LIST

Ha d Crimp Tool 63823-7500

Item

Order Number

Descriptio Qua tity

1 63823-7570 Modular Crimp Head 1

2 63816-0000 Hand Crimp Frame (Short)

3 63823-7575 Locator 1

4 63816-0001 Locking Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

http://www.molex.com

This manual suits for next models

Table of contents

Other molex Crimping Tools manuals

Popular Crimping Tools manuals by other brands

Panduit

Panduit CT-1000 Operation & instruction manual

JST

JST CS 10 instruction manual

Danfoss

Danfoss ET4200 Operator's manual

Tyco Electronics

Tyco Electronics PRO-CRIMPER III instruction sheet

TE Connectivity

TE Connectivity 2063528-1 instruction sheet

Tyco Electronics

Tyco Electronics 69156-1 instruction sheet

CRH

CRH CRL CBLHCT1 instruction manual

Emerson

Emerson Klauke ES 105CFM manual

KIMBALL MIDWEST

KIMBALL MIDWEST 27-798 Operating instructions manual

Danfoss

Danfoss ET4350 Operator's manual

Milwaukee

Milwaukee M18 Operator's manual

HOGERT

HOGERT HT1P169 user manual

Textron

Textron ESG105L instruction manual

Tyco Electronics

Tyco Electronics 90035-3 instruction sheet

Emerson

Emerson Klauke ES 20RMCCFB manual

Continental Refrigerator

Continental Refrigerator PC150HD quick start guide

TE Connectivity

TE Connectivity ERGOCRIMP 1-1579001-3 instruction sheet

Tyco Electronics

Tyco Electronics CERTI-CRIMP 90418-1 instruction sheet

molex 63823-7570 User manual

Popular Crimping Tools manuals by other brands