molex 63823-4500 User guide

Hand Crimp Tool For CTX150 SWS Receptacle Terminals
Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 08-26-1
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT
-
OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAL
0.05
-
0.40 (REF)
SEAL POSITION
HAND CRIMP
TOOL
Appli ation Tooling
Spe ifi ation Sheet Order No. 63823-4500
FEATURES
 A full cycle ratcheting hand tool ensures complete crimps
 Ergonomic soft grip handles for comfortable crimping
 A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
 Right and Left handed applications
 This tool is IPC/WHMA A-620 Class 2 compliant as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: CTX150 SWS Receptacle Terminals 0. 5-0.50 mm2.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diamet
er
Strip Length



Reel
Wire Type
mm²
mm
In.
mm
In.
502 07 502 07- 001
502 07- 006
502 07- 101
502 07- 106
502 07- 401
502 07- 501
T
-
ZHID
0. 5 mm2
1.25
-
1.60
.049
-
.06
4.50-5.00 .177-.197
T
-
ZHIA
0. 5 mm2
1.25
-
1.60
.049
-
.06
T
-
ZHID
0.50 mm2
1
.40
-
1.60
.055
-
.06
4806 4806- 001
4806- 006
4806- 101
4806- 106
4806- 401
4806- 501
T
-
ZHID
0. 5 mm2
1.25
-
1.60
.049
-
.06
4.50-5.00 .177-.197
T
-
ZHIA
0. 5 mm2
1.25
-
1.60
.049
-
.06
T
-
ZHID
0.50 mm2
1.40
-
1.60
.055
-
.06

Customer to cut
off terminal from reel:
0. 0
mm
.012
”) maximum Cut
-
off Tab.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool For CTX150 SWS Receptacle Terminals
Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 08-26-1
WIRE
INSULATION SEAL
0.05
-
0.40
mm
Referen e
SEAL POSTION ON WIRE
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal Series No.
Bell mouth
Condu tor Brush
mm
In.
mm
In.
502 07
0.20-0.55 .008-.022 0.20-1.20 .008-.047
4806
Terminal Series No. Bend up Bend down Twist Roll Seam
Seam shall not be
open and no wire allowed
out of the crimping area
Degree Max.
Degree Max.
502 07
1 1 2
4806
After crimping, the crimp profiles should measure the following:
Terminal
Series No.
Wire Size
Condu tor
Insulation
Pull For e
Minimum
Crimp Height
Crimp Width
Max. Crimp Height Crimp Width
Wire Type
mm²
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
502 07
T
-
ZHID
0
. 5 mm2
0.81
-
0.87
.0 2
-
.0 4
1.65
.065
2.
67
-
2.77
.10
5
-
109
2
.
95
-
.15
.11
6
-
.124
60
1 .5
T
-
ZHIA
0. 5 mm2
0.81
-
0.87
.0 2
-
.0 4
1.65
.065
2.72
-
2.
82
.107
-
1
11
.00
-
.
20
.118
-
.12
6
60
1 .5
T
-
ZHID
0.50 mm2
0.80
-
0.90
.0 1
-
.0 5
1.65
.065
2.72
-
2.82
.107
-
111
.00
-
.20
.118
-
.126
80
18.0
4806
T
-
ZHID
0. 5 mm2
0.81
-
0.87
.0 2
-
.0 4
1.65
.065
2.
67
-
2.77
.10
5
-
109
2.95
-
.15
.11
6
-
.124
60
1 .5
T
-
ZHIA
0. 5 mm2
0.81
-
0.87
.0 2
-
.0 4
1.65
.065
2.72
-
2.
82
.107
-
1
11
.00
-
.
20
.118
-
.12
6
60
1 .5
T
-
ZHID
0.50 mm2
0.80
-
0.90
.0 1
-
.0 5
1.65
.065
2.
72
-
2.82
.107
-
111
.00
-
.20
.118
-
.126
80
18.0
Terminal Series No.
Wire Size
Profile
Single Wire Seal
Wire Type
mm²
0.35 mm2
0.50 mm2
Order No.
Color
Seal Allowed Wire Ø
502 07
T
-
ZHID
0
. 5 mm2
X
See Note See Note See Note
T
-
ZHIA
0
. 5 mm2
X
T
-
ZHID
0.50 mm2
X
4806
T
-
ZHID
0
. 5 mm2
X
T
-
ZHIA
0
. 5 mm2
X
T
-
ZHID
0.50 mm2
X


Cable Seal Position On a Wire
(Before crimping)
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the
insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
. See Product Application Specification AS-502 07-002 for
applicable Seal number, Color and Seal Allowed Wire Diameter.
Note:
A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers available, actual crimp height measurements may very slightly. An
occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must
exceed the Minimum pull force specifications listed.

Hand Crimp Tool For CTX150 SWS Receptacle Terminals
Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page of 7
Revision: A Revision Date: 08-26-1
Figure 4
TERMINAL
WIRE AGAINST
THEWIRE STOP
WIRE AND
SEAL POSITON
WIRE STOP IS
PART OF THE
LOCATOR
TERMINAL
WIRE AND SEAL
POSITIONED IN
LOWER PART OF
THE PUNCHES
OPERATION
CAUTION: Crimp only the Molex terminals
listed in the scope for this tool. Do not crimp
hardened objects as damage can occur to
the tool frame and/or crimp dies.
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. See Figure 1.
Crimping Terminals
1. Select the desired terminal listed in the
preceding charts.
2. Make sure the center of the locator is in the
down position. With the locator attached, push the locator button on the back of the hand tool to bring the
locator forward through the tooling. See Figure 2.
. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the
wire gauge or terminal type markings on the hand tooling. See Figure .
4. Release the locator button, allowing the locator to return to the crimping position.
5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the
upper tooling, until the wire is against the wire stop. See Figure 4.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
TERMINAL
Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN

Hand Crimp Tool For CTX150 SWS Receptacle Terminals
Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 08-26-1
Figure
8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
6. Seal position should be under and inside the punches, keep this position while crimping.
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
8. Remove the crimped terminal from the terminal locator
by pulling on the wire.
9. Visually inspect the crimped terminal for proper crimp
location.
10. On some large O.D. wires, it may not be possible to
insert the wire with the tool partially closed. Those wires
should be inserted with the hand tool in the open
position. Insert the wire above the terminal in the punch
and against the wire stop then close the tool. See
Figure 6.
Lo ator Repla ement
See the parts list on the last page of this document for the proper locator order number. Follow the steps below to
replace the locator.
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in Figure 7A with your thumb and index finger. The lower tabs of the
locator should disengage from the hand tool.
. Lift and pull away from the hand tool. The top locator hooks should slip out of the top slots easily. See Figure
7A.
4. To reinstall the new locator, make sure the hand tool is in the open position.
5. Press the red insert down as far as it will go as shown in Figure 7B.
TERMINAL
Figure 6
WIRE
WIRE STOP

Hand Crimp Tool For CTX150 SWS Receptacle Terminals
Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 08-26-1
MATCH
UP MARKS
FRONT
BACK
Figure 9
6. Holding onto the lower part of the locator with your thumb and index finger, insert the locators top hooks (2)
into the hand tool top slots.
7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To secure the
locator into place, the lower tabs must snap into place on the hand tool frame.
Right or Left Hand Operation
This hand tool has an added feature that can be converted
from a right handed application to a left handed
application. It is necessary to reverse the tooling if using
the left handed application along with the locator. Follow
the steps below:
1. The locator must be removed before reversing the
tooling.
2. Remove the M BHCS which is holding the upper tooling.
. Flip the upper tooling to the opposite side and replace the M BHCS.
Make sure the small markings on the front and back of the hand tool
frame, match up and are on the outside of the hand tool frame. See Figure
8 and 9.
4. Do the same thing with the lower tooling and tighten the M screws. Be
sure the small markings line up.
5. Reinstall the locator by following the Instructions in the locator replacement
section.
Maintenan e
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.
. 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 0 weight
automotive oil) used at the oil points, every 5,000 crimps or 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.
Mis rimps 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 pressing up on the ratchet release lever in
the movable handle. See Figure 11.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11

Hand Crimp Tool For CTX150 SWS Receptacle Terminals
Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 08-26-1
Figure 12
SQUEEZE
THE LINK
IN THE HANDLE
HOLD THE HAND
TOOL IN POSITIN
SETTING WHEEL
RATCHET
RELEASE LEVER
How to Adjust Tool Preload
(See Figure 12)
This hand tool is factory preset to 25-45 LBS.
preload. It may be necessary over the life of
the tool to adjust tool handle preload force.
Listed below are the steps required to adjust
the crimping force of the hand tool to obtain
proper crimp conditions:
1. Hold the hand tool in the palm of your
hand as shown in Figure 12. Using the
index finger squeeze the link towards the
top of the hand tool frame. This will release the preload adjustment wheel.
2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the setting wheel clockwise (CW).
. Release the link to lock the setting wheel in place.
4. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.
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 0
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: 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.
. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
Certifi ation
Molex does not certify or re-certify 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.
% If the tool does not meet minimum pull force values, handle preload should be increased and the pull test
rerun, (See How to Adjust Preload).
% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.

Hand Crimp Tool For CTX150 SWS Receptacle Terminals
Doc No: ATS-6 82 4500 Release Date: 08-26-1 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 08-26-1
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Des ription
Quantity
REF
638
23
-
4
5
00
Hand Crimp Tool
Figure 13
1
6 8
2
-
4
5
75
Locator Assembly
1
2
6 810
-
0104
Spring, Return
1
6 810
-
0105
Spring, Ratchet
1
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