molex 63823-6470 User manual

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 1 of 8
Revision: C Revision Date: 01-03-12
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND
UP
TWISTING
ROLLING
BEND
DOWN
WIRE
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63823-6470
Hand Crimp Tool
Ord r No. 63823-6400
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: PV Solar Pin and Socket Crimp Terminals, 10-1 AWG (6.0-2.5mm²)
T rminal
S ri s No.
T rminal Ord r No. Wir Siz and Typ Insulation Diam t r (r f) Strip L ngth
Loos R l only AWG mm² mm In. mm In.
130196 130196-0310
130196-031 10-12 6.00- .00 7.8 .31 7.00-10.00 .276-.39
130196-0313 130196-0315 1 2.50 6.7 .26 7.00-10.00 .276-.39
130197 130197-0325
130197-03 6 10-12 6.00- .00 7.8 .31 7.00-10.00 .276-.39
130197-0336 130197-03 7 1 2.50 6.7 .26 7.00-10.00 .276-.39
93302 93302-0006 93302-000 10-12 6.00- .00
7.8 .31 7.00-10.00 .276-.39
93302-0005 93302-0003 1 2.50 6.7 .26 7.00-10.00 .276-.39
93303 93303-0005 93303-0003 10-12 6.00- .00
7.8 .31 7.00-10.00 .276-.39
93303-0006 93303-000 1 2.50 6.7 .26 7.00-10.00 .276-.39
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

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 2 of 8
Revision: C Revision Date: 01-03-12
CONDITIONS:
T rminal S ri s No. Wir Siz B ll mouth Cut-off Tab Maximum Conductor Brush
AWG mm² mm In. mm In. mm In.
130196 and 93302 10-1 6.00-2.50 0.20-1.50 .008-.059 0.50 .020 1.00-3.00 .039-.118
130197 and 93303 10-1 6.00-2.50 0.20-1.50 .008-.059 0.50 .020 1.00-3.00 .039-.118
T rminal S ri s No. Wir Siz B nd up B nd down Twist Roll Punch Width (R f)
S am
Seam shall not be open
and no wire allowed out
of the crimping area
Conductor
AWG mm2 D gr D gr mm In
130196 and 93302 10-12 6.00- .00 3 3 8 3.90 .15
1 2.50 3 3 8 2.90 .11
130197 and 93303 10-12 6.00- .00 3 3 8 3.90 .15
1 2.50 3 3 8 2.90 .11
After crimping, the conductor profile should measure the following.
T rminal S ri s No. Wir Siz Conductor Crimp H ight Pull Forc Minimum
AWG mm2 mm In. N Lb.
130196 and 93302
10 6.00 2.10-2.20 .083-.087 356.0 80.0
12 .00 2.00-2.10 .079-.083 312.0 70.0
1 2.50 1.60-1.70 .063-.067 223.0 50.0
130197 and 93303
10 6.00 2.10-2.20 .083-.087 356.0 80.0
12 .00 2.00-2.10 .079-.083 312.0 70.0
1 2.50 1.60-1.70 .063-.067 223.0 50.0
The above specifications are guidelines to an optimum crimp.
Not :
A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires and stranding,
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:
Anvil and Punch Installation
1. Insert the Anvil into the bottom slots of the nest. Install the M x 10 long BHCS and tighten in place.
2. Insert the Punch into the top slots of the nest. Install the M x 18 long BHCS and tighten in place. See Figure
1.
Locator Installation and R moval
Follow the steps below to install or replace the locator. See Figure 2.
To install th locator
1. Position the locator with the hole over the brass pivot shaft and snap it into place.

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 3 of 8
Revision: C Revision Date: 01-03-12
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figur 2
ANVIL
POWER CRIMP
HEAD
Figur
1
PUNCH
M4 X 10mm LONG
BHCS
M4 X 18mm LONG
BHCS
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP LOCATOR TERMINAL
IN PLACE
Figur 4
LOCATOR LATCH
IN OPEN POSITION
To r mov th 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 T rminals
1. Select the desired terminal listed in the preceding
charts.
2. Turn the Locator Lock Latch down to unlock. See
Figure 3.
Figur 3
LATCH LOCKED
LATCH UNLOCKED

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page of 8
Revision: C Revision Date: 01-03-12
Figur 6
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Figur 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
3. Swing the terminal locator away from the crimp tool shown in Figure . Some terminals with large conductor
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.
. 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 10, 12 or 1 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.
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. Crimp 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.
11. Visually inspect the crimped terminal for proper
crimp location.
Not : The tamper proof ratchet action will not release the tool until it has been fully closed.
For th Batt ry Pow r 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.
3. Visually inspect the crimped terminal for proper crimp location.
Figur 7
WIRE
CONDUCTOR ANVIL
LOCATOR
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 5 of 8
Revision: C Revision Date: 01-03-12
Maint nanc
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.
. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams for Crimp Hand Tools Only
(S Figur 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.
3. Wear eye protection at all times.
. Use only the Molex terminals specified for crimping with this tool.
CAUTION: Repetitive use of this tool should be avoided.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 8A
Figur 8B

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 6 of 8
Revision: C Revision Date: 01-03-12
C rtification
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
Ord r No.
Tool
Ord r no.
Tool
D scription
Pow r H ad
Ord r No.
Adapt r
D scription Figur No.
63823-6 70
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 th Tool Kit
Hand Crimp Tool Batt ry Pow r d Tool
Figur 9 Figur 10
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 connected to any power source. Make sure
the power is disconnected.
CAUTION: To prevent injury, keep fingers away from the crimping area when operating this tool.
CAUTION: Wear safety glasses when operating or servicing this tool.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 7 of 8
Revision: C Revision Date: 01-03-12
RATCHET
RELEASE SCREW
Figur 11
M4 X 8mm
LONG BHCS
2
1
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
3
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
It m Numb r Ord r Numb r D scription Quantity
1
63810
-
1000
Hand Crimp Frame (Long)
1
2 63823-6 70 Tool Kit with Locator 1
3 63823-6 75 Locator (only) REF

Hand Tool for PV Solar Pin and Socket Crimp Terminals
Doc No: ATS-638236 HM Release Date: 03-0 -11 UNCONTROLLED COPY Page 8 of 8
Revision: C Revision Date: 01-03-12
Figur 12
1
2
2
M4 by 8mm Long
BHCS
M4 by 18mm Long
BHCS
M4 by 10mm Long
BHCS
1
POWER HEAD PARTS LIST
It m Ord r No Engin ring No. D scription Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63823-6 70 63823-6 70 Tool Kit 1
http://www.molex.com