molex 63823-5570 User manual

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 1 of 9
Revision: A Revision Date: 03-09-11
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
SEAM
BELL MOUTH
WIRE
Application Tooling
Specification Sheet
Tool Kit
Order No. 63823-5570
Hand Crimp Tool
Order No. 63823-5500
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: .250 MP-Lock Terminals for 14-18 AWG Wire.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Reel Form Only
AWG
mm²
mm
In.
mm
In.
57989
57989-9810
14
2.00
2.2-3.4
.087-.134
5.00-5.50
.197-.217
16
1.30
18
0.80
Customer to cut off terminal from reel: 0.50mm (.020”) 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.
TYPE 4C

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 2 of 9
Revision: A Revision Date: 03-09-11
▲Insulation Crimp 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).
CONDITIONS:
After crimping, the conductor profiles should
measure the following (see notes below).
Terminal
Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum
Profile
Height
Width (Ref)
Height
Width (Ref)
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lbs
14
16
18
57989
14
2.00
1.77-1.87
.070-.074
2.75
.108
2.60
.102
4.50
.177
245.17
55.12
X
16
1.30
1.57-1.67
.062-.066
2.75
.108
2.70
.106
4.50
.177
205.94
46.30
X
18
0.80
1.45-1.55
.057-.061
2.75
.108
3.60
.142
4.50
.177
117.68
26.46
X
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.
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, 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 Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 3 of 9
Revision: A Revision Date: 03-09-11
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
To install the locator
1. Position the locator with the hole over the brass pivot shaft and snap it into place.
To remove the locator
1. Open the crimp hand tool.
2. Swing the existing 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 Terminals
1. Select the desired terminal listed in the preceding
charts.
2. Turn the Locator Lock Latch down to unlock. See
Figure 3.
3. Swing the terminal locator away from the crimp tool
shown in Figure 4. Some terminals with large
insulation grips may interfere with the crimp tooling
when swinging the locator into position. The terminal
must then be loaded into the locator in the
closed/crimp position. See Figure 5.
4. Press down on the wire stop on the locator as shown
in Figure1. Insert the proper terminal into the proper
nest opening. Make sure when choosing the nest opening, it will correspond with the A, B or C profile on the
hand tool.
5. Return the locator to its original position.
6. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.
Figure 3
LATCH LOCKED
LATCH UNLOCKED

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 4 of 9
Revision: A Revision Date: 03-09-11
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
TERMINAL
IN PLACE
Figure 4
LOCATOR LATCH
IN OPEN POSITION
Figure 6
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Figure 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
7. Insert the proper wire over the terminal.
8. Gently touch the wire stop with the end of the wire. See Figure 6 and 7.
9. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
10. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
11. Visually inspect the crimped terminal for proper crimp location.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
For the Battery Power 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. The terminal locator can be in either position.
3. Visually inspect the crimped terminal for proper crimp location.

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 5 of 9
Revision: A Revision Date: 03-09-11
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 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 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 8A or 8B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams for Crimp Hand Tools Only
(See Figure 11)
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 11.
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.
WIRE
Figure 7
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
INSULATION ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 8A
Figure 8B

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 6 of 9
Revision: A Revision Date: 03-09-11
3. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
CAUTION: Repetitive use of this tool should be avoided.
Certification
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
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
Adapter
Description
Figure
No.
63923-5570
63810-1050
Hand Crimp Frame (Short)
N/A
N/A
9
63810-1000
Hand Crimp Frame (Long)
N/A
N/A
9
63816-0200
Battery Power Tool (110 V)
63816-0300
Power Crimp Head
10
63816-0250
Battery Power Tool (220 V)
63816-0300
Power Crimp Head
10
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure 9
Figure 10
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 7 of 9
Revision: A Revision Date: 03-09-11
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.

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 8 of 9
Revision: A Revision Date: 03-09-11
RATCHET
RELEASE SCREW
Figure 11
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810-1000
Hand Crimp Frame (Long)
1
2
63823-5570
Tool Kit with Locator
1
3
63811-4773
Locator Base
1
4
63823-5575
Locator (only)
REF

Tool Kit for 250 MP-Lock Terminal
Doc No: ATS-6382355HM Release Date: 03-09-11 UNCONTROLLED COPY Page 9 of 9
Revision: A Revision Date: 03-09-11
Figure 12
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63816-0300
63816-0300
Power Crimp Head
1
2
63823-5570
63823-5570
Tool Kit
1
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