molex 63816-0200 User manual

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 10-13-10
TYPE 4A
Application Tooling
Specification Sheet
Modular Cri p Head
Order No. 63823-5370
Hand Cri p Tool
Order No. 63823-5300
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
% odular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63813-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: 3.96mm (.156”) Pitch Wire-to-Wire and 6.50mm (.256”) Pitch Wire-to-Board Crimp Terminals,
22-26 AWG.
Ter inal
Series
Ter inal Order No. Wire Size  Insulation Dia eter Wire Strip Length
Reel For only AWG 2 In. In.
50598 50598-8100
22 0.35 1.50-1.90 .059-.075
2.70-3.30 .106-.130
24 0.20 1.25-1.60 .049-.063
26 0.12 1.25-1.60 .049-.063
50600 50600-8100
22 0.35 1.50-1.90 .059-.075
24 0.20 1.25-1.60 .049-.063
26 0.12 1.25-1.60 .049-.063
Customer to cut off terminal from reel: 0.25mm (.010”) maximum Cut-off Tab.
 See crimp specification for the individual Insulation Diameter.
DEFINITION OF TERMS
This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
COND.CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 10-13-10
Figure 2
WIRE
TERMINAL
LOCATOR INSULATION
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR ANVIL
CONDUCTOR
PUNCH
WIRE
INSULATION
PUNCH
TERMINAL
WIRE STOP BLADE
Figure 1
▲Insulation Cri p 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:
After crimping, the crimp profiles should measure the following.
Ter inal
Series No
Wire Size Conductor Cri p Insulation Cri p Pull Force
Mini u Profile
Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.)
AWG 2 In. M In. In. In. N Lb. AWG 22 AWG 24 AWG 26
50598
22 0.35 0.87-0.92 .034-.036 1.60 .063 2.30 .091 2.20 .087 39.23 8.82 X
24 0.20 0.80-0.85 .031-.034 1.60 .063 2.15 .085 2.20 .087 29.42 6.61 X
26 0.12 0.76-0.81 .030-.032 1.60 .063 2.00 .079 2.20 .087 14.71 3.31 X
50600
22 0.35 0.87-0.92 .034-.036 1.60 .063 2.30 .091 2.20 .087 39.23 8.82 X
24 0.20 0.80-0.85 .031-.034 1.60 .063 2.15 .085 2.20 .087 29.42 6.61 X
26 0.12 0.76-0.81 .030-.032 1.60 .063 2.00 .079 2.20 .087 14.71 3.31 X
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.
Cri ping Ter inals
1. Lift the wire stop blade up.
2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.
3. Bring down the wire stop blade.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 10-13-10
4. Slide the pre-stripped wire into the wire stop blade. See Figure 1. Be sure to hold the wire in place until the
terminal is fully crimped. See Figure 2.
5. Close the tool until the ratchet releases, the tool handles will then spring open.
6. Lift the wire stop blade up if it is still in down position.
7. Carefully remove the crimped terminal.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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. ake 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.
Miscri ps or Ja s
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 6.
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 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. anually 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 olex terminals specified for crimping with this tool.

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 10-13-10
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. olex 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 olex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
6. olex does not certify crimp hand tools.
CAUTION: olex crimp specifications are valid only when used with olex terminals and tooling.
Applications for the Modular Cri p Head
WARNING: NEVER operate, service, install, or adjust this odular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper anual or Specification Sheet.
See Chart below for the correct anual 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 Wire-to-Wire and Wire-to-Board Terminals
Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 10-13-10
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
L
OCKING
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 odular Crimp Head.
Modular Cri p Head
Order No.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63823-5370
63816-0000 Hand Crimp Frame (Short) N/A N/A 3
63816-0050 Hand Crimp Frame (Long) N/A N/A 3
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 5
Applications for the Modular Cri p Head
Hand Cri p Tool Battery Powered Tool Air Powered Tool
Figure 3 Figure 4 Figure 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
Doc No: ATS-6382353H Release Date: 06-23-10 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 10-13-10
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
M4 X 14
LONG BHCS
2
5
1
PARTS LIST
Hand Cri p Tool 63823-5300
Ite Order Nu ber Description Quantity
1 63823-5370 odular Crimp Head 1 (Ref)
2 63816-0050 Hand Crimp Frame (Long) 1 (Ref)
3 63823-5375 Locator 1
4 63816-0001 Locking Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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