molex 63823-5200 User manual

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal
Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 1 of 7
R vision: A R vision Dat : 06-17-10
HAND CRIMP TOOL
Specification Sheet
Order No. 6 82 -5200
FEATURES
 A full cycl ratch ting hand tool nsur s compl t crimps
 Ergonomic soft grip handl s for comfortabl crimping
 A pr cision us r-fri ndly t rminal locator wir stop holds t rminals in th prop r crimping position
 Right and L ft hand d applications
 This tool is WHMA-IPCA620 Class 2 compliant as indicat d
 This tool is RoHS compliant, how v r RoHS compliant is not r quir d
SCOPE
Products: 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal, 16–20 AWG
Terminal Order No. Wire Size Insulation Diameter Strip Length
Terminal Series No.
Loose Piece Reel AWG mm² mm In. mm In.
50350 50350-9101 50350-9001 16-20 1.30-0.50 1.70-2.60 .067-.102 2.80-3.40 .110-.134
 Custom r to cut off t rminal from r l: 0.30mm (.012”) maximum Cut-off Tab.
DEFINITION OF TERMS
Th abov t rminal drawing is a g n ric t rminal r pr s ntation. It is not an imag of a t rminal list d in th scop .
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
TYPE 4D

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal
Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 2 of 7
R vision: A R vision Dat : 06-17-10
CONDITIONS:
Aft r crimping, th conductor profil s should m asur th following.
Conductor Crimp
Wire Size Height Width (Ref.) Profile
Terminal Series No
AWG mm2 mm In. mm In. 16 18 20
16 1.30 1.32-1.42 .052-.056 1.90 .075 X
18 0.80 1.09-1.19 .043-.047 1.90 .075 X
50350
20 0.50 0.99-1.09 .039-.043 1.80 .071 X
Insulation Crimp
Wire Size Max Height (Ref.)
Width (Ref.)
Pull Force
Minimum
Terminal Series No
AWG mm2 mm In. mm In. N Lb.
16 1.30 3.20 .126 2.30 .091 127.4 28.6
18 0.80 3.00 .118 2.30 .091 88.2 19.8
50350
20 0.50 2.60 .102 2.20 .087 58.8 13.2
OPERATION
CAUTION: Install only Mol x t rminals list d abov with this tool. Do not crimp hard n d obj cts as damag can
occur to th tool or di .
Op n th tool by squ zing th handl s tog th r. At th nd of th closing strok , th ratch t m chanism will
r l as th handl s and th hand tool will spring op n. S Figur 1.
Crimping Terminals
1. S l ct th d sir d t rminal list d
from th pr c ding charts. Th n
install it in th prop r locator (S
chart abov and s Locator
Installation on pag 5).
2. Mak sur th c nt r of th locator is
in th down position. With th
locator attach d, push th locator
button on th back of th hand tool to
bring th locator forward through th
tooling. S Figur 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 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal
Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 3 of 7
R vision: A R vision Dat : 06-17-10
RELEASE
LOCATOR BUTTON
TERMINAL Figure
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. Whil holding in th locator button, load th t rminal into th prop r
n st op ning in th locator, bas d on th wir gaug or t rminal typ
markings on th hand tooling. S Figur 3.
4. R l as th locator button, allowing th locator to r turn to th
crimping position.
5. Clos th tool handl until th first ratch t position ngag s. S
Figur 4.
6. Ins rt th prop rly stripp d wir through th t rminal and against th
wir stop. S Figur 5.
7. Crimp th t rminal by squ zing th tool handl s until th ratch t
m chanism cycl has b n compl t d. R l as th handl s to op n
th jaws.
Not : Th tamp r proof ratch t action will not r l as th tool until it has b n fully clos d.
8. R mov th crimp d t rminal from th t rminal locator by pulling on th wir .
9. Visually insp ct th crimp d t rminal for prop r crimp location.
10. On som larg O.D. wir s, it may not b possibl to ins rt th wir with th tool partially clos d. Thos wir s
should b ins rt d with th hand tool in th op n position. Ins rt th wir abov th t rminal in th punch and
against th wir stop th n clos th tool. S Figur 6.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal
Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 4 of 7
R vision: A R vision Dat : 06-17-10
MATCH
UP MARKS
FRONT BACK
Figure 12
Note:
A crimp h ight chart is provid d with this manual as
R f r nc Only. Du to th wid rang of wir s,
strands, insulation diam t rs, and durom t rs
availabl , actual crimp h ight m asur m nts may
v ry slightly. An occasional, d structiv , pull forc
t st should b pr form d to ch ck hand tool crimp.
Pull Forc valu Must xc d th Minimum pull forc
sp cifications list d.
Locator Replacement
S th parts list on th last pag of this docum nt for th prop r locator ord r numb r. Follow th st ps b low to
r plac th locator.
1. Op n th crimp hand tool.
2. Squ z g ntly on th low r ar a shown
in Figur 7A with your thumb and ind x
fing r. Th low r tabs of th locator
should dis ngag from th hand tool.
3. Lift and pull away from th hand tool. Th
top locator hooks should slip out of th top
slots asily. S Figur 7A.
4. To r install th n w locator, mak sur th
hand tool is in th op n position.
5. Pr ss th r d ins rt down as far as it will
go as shown in Figur 7B.
6. Holding onto th low r part of th locator
with your thumb and ind x fing r, ins rt
th locator top hooks (2) into th hand tool
top slots.
7. Rotat th locator down and pr ss th
low r tabs into th two bottom slots of th
hand tool. To s cur th locator into
plac , th low r tabs must snap into plac
on th hand tool fram .
Right or Left Hand Operation
This hand tool has an add d f atur that can b
conv rt d from a right hand d application to a l ft
hand d application. It is n c ssary to r v rs th
tooling along with th locator if using th l ft hand d
application. Follow th st ps b low:
1. Th locator must b r mov d b for r v rsing th
tooling.
2. R mov th M3 BHCS which is holding th upp r 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 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal
Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 5 of 7
R vision: A R vision Dat : 06-17-10
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
3. Flip th upp r tooling to th opposit sid and r plac th M3 BHCS Mak sur th small markings on th
front and back of th hand tool
fram match up and ar on th
outsid of th hand tool fram .
S Figur 8 and 9.
4. Do th sam thing with th low r
tooling and tight n th M3
scr ws. B sur th small
markings lin up.
5. R install th locator by following
th Instructions in th locator
r plac m nt s ction.
Maintenance
It is r comm nd d that ach op rator
of th tool b mad awar of, and r sponsibl for, th following maint nanc st ps:
1. R mov dust, moistur , and oth r contaminants with a cl an brush, or soft, lint fr cloth.
2. Do not us any abrasiv mat rials that could damag th tool.
3. Mak c rtain all pins; pivot points and b aring surfac s ar prot ct d with a thin coat of high quality machin
oil. Do not oil xc ssiv ly. Th tool was ngin r d for durability but lik any oth r quipm nt it n ds
cl aning and lubrication for a maximum s rvic lif of troubl fr crimping. Light oil (such as 30 w ight
automotiv oil) us d at th oil points,
v ry 5,000 crimps or 3 months, will
significantly nhanc th tool lif .
4. Wip xc ss oil from hand tool,
particularly from crimping ar a. Oil
transf rr d from th crimping ar a
onto c rtain t rminations may aff ct
th l ctrical charact ristics of an
application.
5. Wh n tool is not in us , k p th
handl s clos d to pr v nt obj cts from
b coming lodg d in th crimping di s,
and stor th tool in a cl an, dry ar a.
Miscrimps or Jams
Should this tool v r b com stuck or
jamm d in a partially clos d position, Do Not forc th handl s op n or clos d. Th tool will op n asily by
pr ssing up on th ratch t r l as l v r in th movabl handl . S Figur 11
How to Adjust Tool Preload
(See Figure 12)
This hand tool is factory pr s t to 25-45 LBS. pr load. It may b n c ssary ov r th lif of th tool to adjust tool
handl pr load forc . List d b low ar th st ps r quir d to adjust th crimping forc of th hand tool to obtain
prop r crimp conditions:
RATCHET RELEASE
LEVER
Figure 11
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY MONTHS OR
5,000 CRIMPS)
Figure 10

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal
Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 6 of 7
R vision: A R vision Dat : 06-17-10
1. Hold th hand tool in th palm of your hand as shown in Figur 12. Using th ind x fing r squ z th link
towards th top of th hand tool fram . This will r l as th pr load adjustm nt wh l.
2. Rotat th s tting wh l count r-clockwis (CCW) to incr as handl forc . Th numb rs will display high r.
To d cr as handl forc , rotat th s tting wh l clockwis (CW).
3. R l as th link to lock th s tting wh l in plac .
4. Ch ck th crimp sp cifications or conduct a pull t st aft r tool handl pr load forc is adjust d.
Warranty
This tool is for l ctrical t rminal crimping purpos s only. This tool is mad of th b st quality mat rials. All vital
compon nts ar long lif t st d. All tools ar warrant d to b fr of manufacturing d f cts for a p riod of 30
days. Should such a d f ct occur, w will r pair or xchang th tool fr of charg . This r pair or xchang will
not b applicabl to alt r d, misus d, or damag d tools. This tool is d sign d for hand us only. Any clamping,
fixturing, or us of handl xt nsions voids this warranty.
CAUTION: Mol x crimp sp cifications ar valid only wh n us d with Mol x t rminals and tooling.
CAUTIONS:
1. Manually pow r d hand tools ar int nd d for low volum or fi ld r pair. This tool is NOT int nd d for
production us . R p titiv us of this tool should b avoid d.
2. Insulat d rubb r handl s ar not prot ction against l ctrical shock.
3. W ar y prot ction at all tim s.
4. Us only th Mol x t rminals sp cifi d for crimping with this tool.
Certification
Mol x do s not c rtify or r -c rtify hand tools but rath r suppli s th following guid lin s for custom rs to r -c rtify
hand tools.
% This tool is qualifi d to pull forc only. To r -c rtify, crimp a t rminal to a wir , which has b n stripp d
12.7mm (1/2”) long, so th r is no crimping of th insulation. Pull th t rminal and wir at a rat no fast r than
25mm (1.00”) p r minut . S th Mol x w b sit for th Quality Crimp Handbook for mor information on pull
t sting.
% If th tool do s not m t minimum pull forc valu s, handl pr load should b incr as d and th pull t st
r run, (S How to Adjust Pr load).
% Wh n th hand tool is no long r capabl of achi ving minimum pull forc , it should b tak n out of s rvic and
r plac d.

Hand Crimp Tool for 2.50mm (.098”) / 3.00mm (.118”) Pitch Wir -to-Board F mal Crimp T rminal
Doc No: ATS-638235200 R l as Dat : 06-17-10 UNCONTROLLED COPY Pag 7 of 7
R vision: A R vision Dat : 06-17-10
RATCHET
RELEASE LEVER
2
Figure 1
1
PARTS LIST
Item Number Order Number Description Quantity
REF 63823-5200 Hand Crimp Tool Figur 13
1 63823-5275 Locator Ass mbly (R d) 1
2 63810-0104 Spring, R turn 1
3 63810-0105 Spring, Ratch t 1
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