molex 63823-5100 User guide

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal
Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 1 of 7
Revision: B Revision Date: 11-23-11
TYPE 4D
HAND CRIMP
TOOL
Application Tooling
Specification Sheet Or er No. 63823-5100
FEATURES
 full cycle ratcheting hand tool ensures complete crimps
 Ergonomic soft grip handles for comfortable crimping
 precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
 Right and Left handed applications
 This tool is WHM -IPC 620 Class 2 compliant as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal, 22-26 WG.
Terminal Series No.
Terminal Or er No. Wire Size Insulation Diameter Strip Length
Loose Piece Reel AWG mm² mm In. mm In.
50372 50372-8100 50372-8000 22-26 0.35-0.12 0.95-1.40 .037-.055 1.30-1.80 .051-.071
56161 56161-8181 56161-8081 22-26 0.35-0.12 1.05-1.40 .041-.055 1.30-1.80 .051-.071
 Customer to cut off terminal from reel: 0.15mm (.006”) 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.
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal
Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: 11-23-11
CONDITIONS:
fter crimping, the conductor profiles should measure the following.
Terminal Series No
Wire Size Con uctor Crimp Profile
Height Wi th (Ref.)
AWG mm2 mm In. mm In. 22 24 26
50372
56161
22 0.35 0.70-0.75 .027-.029 1.20 .047 X
24 0.20 0.62-0.67 .024-.026 1.20 .047 X
26 0.12 0.57-0.62 .022-.024 1.20 .047 X
Terminal Series No
Wire Size Insulation Crimp Pull Force
Minimum
Max Height (Ref.) Wi th (Ref.)
AWG mm2 mm In. mm In. N Lb.
50372
56161
22 0.35 1.30 .051 1.45 .057 39.2 8.8
24 0.20 1.10 .043 1.45 .057 29.4 6.6
26 0.12 1.00 .039 1.45 .057 19.6 4.4
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
Open the tool by squeezing the handles together. t 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
from the preceding charts. Then
install it in the proper locator (See
chart above and see Locator
Installation on page 5).
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.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal
Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: 11-23-11
RELEASE
LOCATOR BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
3. While holding in the locator button, 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 3.
4. Release the locator button, allowing the locator to return to the
crimping position.
5. Close the tool handle until the first ratchet position engages. See
Figure 4.
6. Insert the properly stripped wire through the terminal and against the
wire stop. See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has bee n 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.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal
Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: 11-23-11
MATCH
UP MARKS
FRONT
BACK
Figure 12
Note:
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. n occasional, destructive, pull force
test should be preformed to check hand tool crimp.
Pull Force value Must exceed the Minimum pull force
specifications listed.
Locator Replacement
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 7 with your thumb and index finger.
The lower tabs of the locator should
disengage from the hand tool.
3. Lift and pull away from the hand tool. The
top locator hooks should slip out of the top
slots easily. See Figure 7 .
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.
6. Holding onto the lower part of the locator
with your thumb and index finger, insert the
locator 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 Han 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 along with the locator if using the left handed
application. Follow the steps below:
1. The locator must be removed before reversing the
tooling.
2. Remove the M3 BHCS which is holding the upper tooling.
TERMINAL
Figure 6
WIRE
WIRE STOP
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal
Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: 11-23-11
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
3. Flip the upper tooling to the
opposite side and replace the M3
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 M3 screws.
Be sure the small markings line up.
5. Reinstall the locator by following
the Instructions in the locator
replacement section.
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. 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 pressing up on the ratchet release lever in the movable handle. See Figure 11
RATCHET RELEASE
LEVER
Figure 11
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10

Hand Crimp Tool for 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal
Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 6 of 7
Revision: B Revision Date: 11-23-11
How to A just Tool Preloa (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).
3. 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. ll vital
components are long life tested. ll 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. ny 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.
3. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
Certification
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 djust 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 2.0 W/B Crimp Receptacle Terminal & SMEC Crimp Receptacle Terminal
Doc No: TS-638235100 Release Date: 06-17-10 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: 11-23-11
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Or er Number Description Quantity
REF 63823-5100 Hand Crimp Tool Figure 13
1 63823-5175 Locator ssembly (Red) 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
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