molex 63823-6370 User manual

Hand Crimp Tool: for Quick Disconnect, High Reliability Terminal (HRT)
Doc o: ATS-6382363HM Release Date: 09-16-10 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 10-14-10
TYPE 4A
INSULATION
CRIMP
▲
SEE NOTE
BRUSH
STRIP
LENGTH
TERMINAL
STRIP
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
SEAM
BELL MOUTH
WIRE
Applicatio Tooli g
Specificatio Sheet
Modular Crimp Head
Order No. 63823-6370
Ha d Crimp Tool
Order No. 63823-6300
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
% Modular Crimp Head is removable and can be use in the Air Powered Tool Order o.63816-0100,
accompanied by Air Powered Crimp Adapter (Order o. 63816-0700).
% Can also be used in the Battery Powered Tool Order o.63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order o. 63816-0600).
SCOPE
Products: Quick Disconnect, High Reliability Terminal (HRT), Female for 0.50-1.00mm² Wire.
Termi al Series No.
Termi al Order No. Wire Size I sulatio Diameter Strip Le gth
Reel Form O ly mm² / AWG mm I . mm I .
94512 94512-0100 94512-0101
0.50
2.60 Max .102 Max 5.30-6.30 .209-.248 0.75
1.00
Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.
See crimp specification for the individual Insulation Diameter.
DEFINITION OF TERMS

Hand Crimp Tool: for Quick Disconnect, High Reliability Terminal (HRT)
Doc o: ATS-6382363HM Release Date: 09-16-10 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 10-14-10
▲I sulatio 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).
CRIMP SPECIFICATIONS:
After crimping, the crimp profiles should measure the following.
Termi al Series No.
Wire Size
Co ductor Crimp Profile
Height Width
mm2 mm I . mm I . 0.5 0.75 1.0
94512
0.50 1.40-1.50 .055-.059 2.40 .095 X
0.75 1.45-1.55 .057-.061 2.40 .095 X
1.00 1.55-1.65 .061-.065 2.40 .095 X
Termi al
Series No.
Wire Size
I sulatio Crimp Pull Force Mi imum
Height (Ref) Width (Ref)
mm2 mm I . mm I . N Lb.
94512
0.50 2.90 .114 3.50 .138 78.45 17.64
0.75 3.10 .122 3.50 .138 117.68 26.46
1.00 3.10 .122 3.50 .138 156.91 35.27
■Tool Qualification otes:
1. Pull Force should be measured with no influence from the
insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
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.
Crimpi g Termi als
1. Lift the wire stop blade up.
2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.
3. Bring down the wire stop blade.
4. Slide the pre-stripped wire into the wire stop blade. See Figure 1. Be sure to hold the wire in place until the
terminal is fully crimped. See Figure 2.
5. Close the tool until the ratchet releases, the tool handles will then spring open.
6. Lift the wire stop blade up if it is still in down position.
7. Carefully remove the crimped terminal.
TERMINAL
PRE-STRIPPED
WIRE
LOCATOR
Figure 1
WIRE STOP
BLADE
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool: for Quick Disconnect, High Reliability Terminal (HRT)
Doc o: ATS-6382363HM Release Date: 09-16-10 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 10-14-10
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Mai te a ce
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 lifting the ratchet release lever. See Figure 6.
Warra ty
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 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. Any clamping,
fixturing, or use of handle extensions voids this warranty.
CAUTION: Repetitive use of this tool should be avoided.
CAUTIONS:
1. Manually powered hand tools are intended for low volume or field repair. This tool is OT 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.
Figure 2
CONDUCTOR
PUNCH
WIRE
LOCATOR
TERMINAL
INSULATION
PUNCH
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
RETAINER
SPACER

Hand Crimp Tool: for Quick Disconnect, High Reliability Terminal (HRT)
Doc o: ATS-6382363HM Release Date: 09-16-10 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 10-14-10
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all
insulation sizes.
4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips
on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
6. Molex does not certify crimp hand tools.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
Applicatio s for the Modular Crimp Head
WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper Manual or Specification Sheet.
See Chart below for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging or turn off the Actuator from its power source.
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.

Hand Crimp Tool: for Quick Disconnect, High Reliability Terminal (HRT)
Doc o: ATS-6382363HM Release Date: 09-16-10 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 10-14-10
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POWER
CRIMP
ADAPTER
The chart below shows all applications for this Modular Crimp Head.
Modular Crimp Head
Order No.
Tool
Order o.
Tool
Descriptio
Adapter
Order No.
Adapter
Descriptio
Figure
No.
63823-6370
63816-0000 Hand Crimp Frame (Short) /A /A 3
63816-0050 Hand Crimp Frame (Long) /A /A 3
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 4
63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 5
Applicatio s for the Modular Crimp Head
Ha d Crimp Tool Battery Powered Tool Air Powered Tool
Figure 3 Figure 4 Figure 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool: for Quick Disconnect, High Reliability Terminal (HRT)
Doc o: ATS-6382363HM Release Date: 09-16-10 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 10-14-10
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
2
5
1
M4 X 14mm
LONG BHCS
PARTS LIST
Ha d Crimp Tool 63823-6300
Item Order Number Descriptio Qua tity
1 63823-6370 Modular Crimp Head 1
2 63816-0050 Hand Crimp Frame (Long) 1
3 63823-6375 Locator 1
4 63816-0001 Locking Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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