molex 63823-4100 User manual

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 01-19-11
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT
-
OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63823-4170
Hand Crimp Tool
Ord r No. 63823-4100
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: CP 2.8 receptacle for 12 - 10 AWG type TXL wire and >3 - 5 mm2 type ID and IR wire with 2.80mm
(.110") CMC Wire Seal (See Note  )
T rminal S ri s No.
T rminal Ord r No
.
Wir Siz
and Typ
Insulation Diam t r
Strip
L ngth

Availabl in R l only
AWG
mm²
mm
In.
mm
In.
6 32 6 32 -1019 6 32 -1119 12-10 TXL >3 – 5 Type ID & IR 3. – .0 .13 - .157 .90-5.10 .193-.201
6 32 -2019 6 32 -2119

Customer to cut off terminal from r
eel: 0.30mm (.012
”) maximum Cut
-
o
ff Tab.
Not : Terminal will accommodate the thin wall small insulation with the TXL type American wires and the ID or IR type metric wires.
 For TXL-12AWG wire uses Seal color GREY, For TXL-10AWG, mm2 and 5mm2 wires use Seal color BLUE.
DEFINITION OF TERMS
TYPE 4C

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 01-19-11
ANVILS
POWER
CRIMP
HEAD
Figur
1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
CRIMP SPECIFICATION
T rminal S ri s No.
B ll Mouth
B nd up B nd down
Twist Roll
Conductor Brush
mm
In.
D gr
D gr
mm
In.
6 32
0.
1
-
0.5
.0
0
-
.020
2
2
2
3
0.2
-
0.6
.008
-
.02
S am:
Seam shall not be open and no wire allow
ed out of the crimping area.
After crimping, the conductor profiles should measure the following (See notes below).
T rminal
S ri s No.
Wir Siz
Conductor
Insulation
Pull Forc
Minimum Profil
Crimp H ight
(R f)
Crimp Width
(R f)
Crimp H ight
(R f)
C
rimp Width
(R f)
AWG mm2 mm In. mm In. mm In. mm In. N Lb
4
mm
2
12 AWG
5
mm
2
10AWG
6 32
12
3.31
2.00
-
2.10
.079
-
.083
3. 9
.137
5.05
–
5.35
.199
-
.21
1
5.06
.199
3
12
70
.0
X
2.00
-
2.10
.079
-
.083
3. 9
.137
5.05
–
5.35
.199
-
.211
5.06
.199
320
7
1.9
X
10
5.26
2.10
-
2.20
.083
-
.087
3.50
.138
5.25
–
5. 5
.207
-
.215
5.07
.200
3
56
80
.0
X
5
2.10
-
2.20
.083
-
.087
3.50
.138
5.25
–
5. 5
.207
-
.215
5.07
.200
360
80.9
X
Tool Qualification Not s:
1. Pull Force should be measured with no influence from the insulation crimp.
2. 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, strands,
insulation diameters, and durometers, 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:
Anvils and Punch s Installation
1. Insert the Anvils into the bottom slots of the nest. Install
the M x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install
the M x 18 long BHCS and tighten in place. See
Figure 1.
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 Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 01-19-11
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figur
2
SWING OPEN
T
ERMINAL
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 and unlock the locator latch.
2. Swing the 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. Unlock the locator latch and swing the terminal locator away from the crimp tool shown in Figure 3 and .
3. Press down on the wire stop on the locator as shown in
Figure . Insert the proper terminal into the proper
nest opening. Make sure when choosing the nest
opening, it will correspond with the correct profile on
the hand tool.
. Return the locator to closed position. Make sure the locator latch is in lock position. Insert the proper wire with
the seal over the terminal. Gently touch the wire stop with the end of the wire and align the seal with the grips
on the terminal. See Figure 5 and 6.
Figur 3
LATCH LOCKED
LATCH UNLOCKED

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page of 8
Revision: A Revision Date: 01-19-11
LOCATOR
Figur 6
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
SEAL
TERMINAL
PRE
-
S
TRIPPED
WIRE WITH SEAL
Figur 5
WIRE STOP
BLADE
5. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
6. Unlock the locator latch and swing the locator open.
Not : The tamper proof ratchet action will not release the tool until it has been fully closed.
7. Remove the crimped terminal from the
terminal locator by pressing down on the
wire stop and gently pulling on the wire.
8. Visually inspect the crimped terminal for an
acceptable crimp.
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 an
acceptable crimp.
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
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 7A
Figur 7B

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 01-19-11
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 7A or 7B 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 10)
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 10.
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.
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- 170
6381
0
-
1050
Hand Crimp Frame (Short
)
N/A
N/A
8
6381
0
-
100
0
Hand Crimp Frame (Long)
N/A
N/A
8
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp Head
9
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp Head
9

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 01-19-11
Applications for th Tool Kit
Hand Crimp Tool
Batt r
y Pow r d Tool
Figur
8
Figur
9
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 into any power source. Make sure the
power is turned off.
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.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 01-19-11
RATCHET
RELEASE SCREW
Figur 10
M4 X 8mm
LONG BHCS
2
1
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
3
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
It m Numb r
Ord r Numb r
D scription
Quantity
1
63810
-
1000
Hand Crimp Fr
ame (Long)
1
2
638
23
-
1
70
Tool Kit with
Locator
1
3
63823
-
175
Locator (only)
REF

Hand Crimp Tool for CP 2.8 Receptacle Crimp Terminals
Doc No: ATS-63823 1HM Release Date: 01-19-11 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 01-19-11
Figur 11
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
It m
Ord r No
Engin ring No.
D scription
Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63823- 170 63823- 170
Tool Kit with
Locator
1
http://www.molex.com