molex 63823-6900 User manual

Hand Crimp Tool for Mini KK Crimp Terminals
Doc No: ATS-6382369HM Release Da e: 02-24-11 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Da e: 02-24-11
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Application Tooling
Specification S eet
Modular Crimp Head
Order No. 63823-6970
Hand Crimp Tool
Order No. 63823-6900
FEATURES
% A full cycle ra che ing hand ool ensures comple e crimps
% Ergonomically designed sof handles
% Precisely designed crimping profiles wi h simple con ac posi ioning
% Easy handling due o ou s anding force ra io
% A-620 Class 3 complian and RoHS complian
% Modular Crimp Head is removable and can be use in he Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adap er (Order No. 63816-0700).
% Can also be used in he Ba ery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),
accompanied by Ba ery Powered Crimp Adap er (Order No. 63816-0600).
SCOPE
Produc s: Mini KK Crimp Terminal, 22-28 AWG.
Terminal
Series No.
Terminal Order No. Wire Size Insulation Diameter Strip Lengt
Reel Loose AWG mm² mm In. mm In.
5659 08-07-0038 08-07-0039 22-28 0.35-0.08 1.20-1.70 .047-.067 2.50-3.00 .098-.118
Cus omer o cu off erminal from reel: 0.50mm (.020”) maximum Cu -off Tab.
See Condi ions on page 2.
DEFINITION OF TERMS
The above erminal drawing is a generic erminal represen a ion. I is no an image of a erminal lis ed in he scope.
TYPE 4A

Hand Crimp Tool for Mini KK Crimp Terminals
Doc No: ATS-6382369HM Release Da e: 02-24-11 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Da e: 02-24-11
▲Insulation Crimp Note:
Due o he erminal’s insula ion grip design and/or
insula ion diame er range, his ool uses “overlap”
form geome ry in he insula ion punch. This
produces an overlap insula ion crimp (A620 –
complian ). While he insula ion punch profile may
appear “lopsided”, his is a normal condi ion for his
ool. See figure o he righ . (Some ools wi h
mul iple crimp pocke s may no have he “overlap”
profile on all pocke s).
CRIMP SPECIFICATION
Af er crimping, he crimp profiles should measure he following (see no es on page 4).
Terminal
Series No.
Wire Size Conductor Crimp Profile
Heig t Widt (Ref.)
AWG mm2 mm In. mm In. 22 24 26 28
5659
22 0.35 0.82-0.87 .032-.034 1.40 .055 X
24 0.20 0.75-0.80 .030-.032 1.40 .055 X
26 0.12 0.70-0.75 .028-.030 1.40 .055 X
28 0.08 0.66-0.71 .026-.028 1.40 .055 X
Terminal
Series No.
Wire Size Insulation Diameter





Insulation Crimp Pull Force
Minimum
Heig t (Ref.) Widt (Ref.)
AWG mm2 mm In. mm In. mm In. N Lb.
5659
22 0.35 1.60-1.70 .063-.067 1.70 .067 1.85 .073 39.23 8.8
24 0.20 1.40-1.50 .055-.059 1.65 .065 1.85 .073 29.42 6.6
26 0.12 1.30-1.45 .051-.057 1.50 .059 1.75 .069 19.61 4.4
28 0.08 1.20-1.30 .047-.051 1.50 .059 1.75 .069 9.81 2.2
Tool Qualification Notes:
1. Pull Force should be measured wi h no
influence from he insula ion crimp.
2. The above specifica ions are guidelines o
an op imum crimp.
OPERATION
Open he ool by squeezing he handles
oge her, a he end of he closing s roke, he
ra che mechanism will release he handles,
and he hand ool will spring open.
1. Wi h he hand ool in he open posi ion,
pivo he erminal loca or open by pulling up
on he loca or knob and lif he wire s op
blade up. See Figure 1.
TERMINAL
SEATED IN
LOCATOR
SWING
LOCATOR
OPEN
Figure 1
HAND TOOL
OPEN
WIRE
STOP BLADE
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for Mini KK Crimp Terminals
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Revision: A Revision Da e: 02-24-11
WIRE
CONDUCTOR
PUNCH
TERMINAL
WIRE STOP
BLADE
Figure 2 Figure 3
WIRE
TERMINAL
LOCATOR
INSULATION
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR
ANVIL
CONDUCTOR
PUNCH
2. Inser he erminal in o he correc profile un il he erminal is fully sea ed and s ops. Make sure he wire
s op blade is fully sea ed on he erminal behind he conduc or grip sec ion.
3. Gen ly pivo he loca or closed.
4. Bring down he wire s op blade.
5. Slide he pre-s ripped wire in o he erminal; make sure o aim he wire brush owards he ip poin on he
wire s op blade. See Figure 2. Align he wire so ha i is parallel and si ing in o he erminal. Main ain a
ligh and cons an pressure on he wire ha is sea ed in he erminal a all imes. (Do no le go of he
wire.) Be sure o hold he wire and erminal in place un il he erminal is fully crimped. See Figure 3.
6. Close he ool un il he ra che releases.
7. Lif he wire s op blade up.
8. Carefully remove he crimped erminal.
Note: To main ain good brush con rol and a consis en bell mou h he crimping ins ruc ions mus be
followed.
Note: The amper proof ra che ac ion will no release he ool un il i has been fully closed.
Note: To main ain good brush con rol and a consis en bell mou h he crimping ins ruc ions mus be followed.
Terminal Locator Replacement/C ange Over
This sec ion describes he procedure for changing loca ors.
Removal
1. Wi h he ool in he open posi ion, pivo he erminal loca or ou ward.
2. Remove he M4 BHCS. See Figure 4.
Installation
1. Place he proper loca or, (See Char on page 2), on he hand ool.
Ins all he M4 BHCS. See Figure 4.
2. Tigh en he screw enough o hold he loca or. Make sure he loca or
can s ill floa freely wi h hand pressure. M4 BHCS
PIVOT LOCATOR
Figure 4

Hand Crimp Tool for Mini KK Crimp Terminals
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Revision: A Revision Da e: 02-24-11
INCORRECT
Figure 5
CORRECT INCORRECT
3. Inser he proper erminal fully in o he correc profile slo un il he erminal is fully sea ed and s ops. Then
gen ly pivo he loca or closed.
4. Wi h hand pressure, slowly slide he loca or o he correc posi ion. See Figure 5.
5. Gen ly pivo he loca or open wi hou dis urbing he loca ion.
6. Hold he loca or firmly in place and slowly igh en he M4 BHCS.
Maintenance
I is recommended ha each opera or of he ool be made
aware of, and responsible for, he following main enance
s eps:
1. Remove dus , mois ure, and o her con aminan s wi h a
clean brush, or sof , lin free clo h.
2. Do no use any abrasive ma erials ha could damage he
ool.
3. Make cer ain all pins; pivo poin s and bearing surfaces
are pro ec ed wi h a hin coa of high quali y machine oil.
Do no oil excessively. The ool was engineered for
durabili y bu like any o her equipmen i needs cleaning and lubrica ion for a maximum service life of rouble
free crimping. Ligh oil (such as 30 weigh au omo ive oil) used a he oil poin s, every 5,000 crimps or 3
mon hs, will significan ly enhance he ool life.
4. Wipe excess oil from hand ool, par icularly from crimping area. Oil ransferred from he crimping area on o
cer ain ermina ions may affec he elec rical charac eris ics of an applica ion.
5. When ool is no in use, keep he handles closed o preven objec s from becoming lodged in he crimping dies,
and s ore he ool in a clean, dry area.
Miscrimps or Jams
Should his ool ever become s uck or jammed in a par ially closed posi ion, Do Not force he handles open or
closed. The ool will open easily by lif ing he ra che release lever. See Figure 9.
Warranty
This ool is for elec rical erminal crimping purposes only. This ool is made of he bes quali y ma erials. All vi al
componen s are long life es ed. All ools are warran ed o be free of manufac uring defec s for a period of 30
days. Should such a defec occur, we will repair or exchange he ool free of charge. This repair or exchange will
no be applicable o al ered, misused, or damaged ools. This ool is designed for hand use only. Any clamping,
fix uring, or use of handle ex ensions voids his warran y.
CAUTION: Repe i ive use of his ool should be avoided.
CAUTIONS:
1. Manually powered hand ools are in ended for low volume or field repair. This ool is NOT in ended for
produc ion use. Repe i ive use of his ool should be avoided.
2. Insula ed rubber handles are no pro ec ion agains elec rical shock.
3. Wear eye pro ec ion a all imes.
4. Use only he Molex erminals specified for crimping wi h his ool.

Hand Crimp Tool for Mini KK Crimp Terminals
Doc No: ATS-6382369HM Release Da e: 02-24-11 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Da e: 02-24-11
Notes:
1. This ool should only be used for he erminals and wire gauges specified on his shee .
2. This ool is no adjus able for crimp heigh ; however crimp force is adjus able (See ins ruc ions above).
Varia ions in ools, erminals, wire s randing, and insula ion ypes may affec crimp heigh .
3. This ool is in ended for s andard conduc or sizes. I may no give a good insula ion crimp suppor for all
insula ion sizes.
4. Molex does no repair hand ools (see warran y above). The replacemen par s lis ed are he only par s
available for repair. If he handles or crimp ooling is damaged or worn, a new ool mus be purchased.
5. Pull force should be used as he final cri eria for an accep able crimp. Pull force is measured wi h no
influence from he insula ion crimp. The insula ion should be s ripped long (1/2 in.) so he insula ion grips
on he erminal do no grip he wire insula ion or he conduc or. Refer o Molex Quali y Crimping
Handbook 63800-0029 for addi ional informa ion on crimping and crimp es ing.
6. Molex does no cer ify crimp hand ools.
CAUTION: Molex crimp specifica ions are valid only when used wi h Molex erminals and ooling.
Applications for t e Modular Crimp Head
WARNING: NEVER opera e, service, ins all, or adjus his Modular Crimp Head wi hou proper ins ruc ion
and wi hou firs reading and unders anding he ins ruc ions in he proper Manual or Specifica ion Shee .
See Char below for he correc Manual or Specifica ion Shee .
WARNING: NEVER ins all ooling or service his ool while i is in o any power source. Disconnec he
power by unplugging or urn off he Ac ua or from i s power source.
CAUTION: Keep fingers away from he crimping area when opera ing his ool. I may cause severe injury.
CAUTION: Wear safe y glasses when opera ing or serving his ool.

Hand Crimp Tool for Mini KK Crimp Terminals
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Revision: A Revision Da e: 02-24-11
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 char below shows all applica ions for his Modular Crimp Head.
Modular Crimp Head
Order No.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
63823-6970
63816-0000 Hand Crimp Frame (Shor ) N/A N/A 6
63816-0050 Hand Crimp Frame (Long) N/A N/A 6
63816-0200 Ba ery Power Tool (110 V) 63816-0600 Ba ery Power Crimp Adap er 7
63816-0250 Ba ery Power Tool (220 V) 63816-0600 Ba ery Power Crimp Adap er 7
63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adap er 8
Applications for t e Modular Crimp Head
Hand Crimp Tool Battery Powered Tool Air Powered Tool
Figure 6 Figure 7 Figure 8
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for Mini KK Crimp Terminals
Doc No: ATS-6382369HM Release Da e: 02-24-11 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Da e: 02-24-11
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
LOCATOR
2
1
4
Figure 9
M4 X 8mm
LONG BHCS
3
5
6
PARTS LIST
Hand Crimp Tool 63823-6900
Item Order Number Description Quantity
1 63823-6970 Modular Crimp Head 1
2 63816-0000 Hand Crimp Frame (Shor ) 1
3 63823-6975 Loca or 1
4 63816-0001 Locking Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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