molex 63823-9100 User manual

Hand Crimp Tool for 36P Robot Connector Plug and Receptacle Terminals
Doc No: ATS-63 239100 Release Date: 04-11-12 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 04-11-12
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP HEIGHT CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
INSULATION
CRIMP
HAND CRIMP
TOOL
Application Tooling
Sp cification Sh t
Ord r No. 63823-9100
FEATURES
 A full cycle ratcheting hand tool ensures complete crimps
 Ergonomic soft grip handles for comfortable crimping
 A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
 Right or left handed operation
 This tool is IPC/WHMA A-620 Class 2 compliant
SCOPE
Products: 36P Robot Connector Plug and Receptacle Terminals for 16, 1 , and 19AWG wires.
T rminal
S ri s No.
T rminal Ord r No. Wir Siz Insulation Diam t r Strip L ngth
Loos Pi c 

R l AWG mm² mm In. mm In.
503195 503195-1100
503195-1000 16 1.30 2.55 Max 0.10 3.90-4.40
.154-.173
503195-1099 1 0.90 2.15 Max 0.0
503196 503196-1100 503196-1000 19 0.75 2.10 Max 0.0 3.90-4.40 .154-.173
Customer to cut off terminal from reel: 0.20mm (.00 ”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool for 36P Robot Connector Plug and Receptacle Terminals
Doc No: ATS-63 239100 Release Date: 04-11-12 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 04-11-12
▲Insulation Crimp Not :
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.
CRIMP SPECIFICATIONS
After crimping, the crimped terminals should
measure as follows:
T rminal
S ri s No.
Wir Siz Conductor Crimp Profil
H ight (R f.) Width (R f.)
AWG mm2 mm In. mm In. “16” “19-18”
503195
503196
16 1.30 1.3 – 1.4 .054 – .05
2.20 .0 7
X
1 0.90 1.21 – 1.31 .04 – .052 X
19 0.75 1.1 – 1.2 .046 – .050 X
T rminal
S ri s No.
Wir Siz Insulation Crimp Pull Forc
Minimum
H ight (R f.) Width (R f.)
AWG mm2 mm In. mm In. N Lb.
503195
503196
16 1.30 3.00 – 3.20 0.12 – 0.13
3.10 .120
127.0 29
1 0.90 2.60 – 2. 0 0.10 – 0.11 .2 20
19 0.75 2.60 – 2. 0 0.10 – 0.11 7 1
CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as
damage can occur to the tool frame and/or crimp dies.


 Tool Qualification Not s:
1. Pull Force should be measured with no influence from the insulation crimp.
2. 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, strands, insulation diameters, and
durometer available, actual crimp height
measurements may very slightly. An occasional,
destructive, pull force test should be performed to
check hand tool crimp. Pull Force value must
exceed the minimum pull force specification.
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. See Figure 1.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figur 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figur 1

Hand Crimp Tool for 36P Robot Connector Plug and Receptacle Terminals
Doc No: ATS-63 239100 Release Date: 04-11-12 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 04-11-12
PRE-STRIPPED WIRE
TERMINAL
Figur 5
TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE
TERMINAL
Figur 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
Crimping T rminals
1. Select the desired terminal listed in the preceding charts.
2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button
on the back of the hand tool to bring the locator forward through the tooling. See Figure 2.
3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the
wire gauge or terminal type markings on the hand tooling. See Figure 3.
4. Release the locator button, allowing the locator to return to the crimping
position.
5. Close the tool handle until the first ratchet position engages. See Figure
4.
6. Insert the properly stripped wire through the terminal and against the
wire stop. See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. Release the handles to open
the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
. Remove the crimped terminal from the terminal locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper crimp location.
10. On some large O.D. wires, it may not be possible to insert the wire with the tool partially closed. Those wires
should be inserted with the hand tool in the open position. Insert the wire above the terminal in the punch and
against the wire stop then close the tool. See Figure 6.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figur 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool for 36P Robot Connector Plug and Receptacle Terminals
Doc No: ATS-63 239100 Release Date: 04-11-12 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 04-11-12
Figur 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figur 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figur 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
Locator R plac m nt
See the parts list on the last page of this document for the
proper locator order number. Follow the steps below to
replace the locator.
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in Figure 7A
with your thumb and index finger. The lower tabs of
the locator should disengage from the hand tool.
3. Lift and pull away from the hand tool. The top locator
hooks should slip out of the top slots easily. See
Figure 7A.
4. To reinstall the new locator, make sure the hand tool is in the open position.
5. Press the red insert down as far as it will go as shown in Figure 7B.
6. Holding onto the lower part of the locator with your thumb and index finger, insert the locators top hooks (2)
into the hand tool top slots.
7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To secure the
locator into place, the lower tabs must snap into
place on the hand tool frame.
Right or L ft Hand Op ration
This hand tool has an added feature that can be
converted from a right handed application to a left
handed application. It is necessary to reverse the
tooling if using the left handed application along with
the locator. Follow the steps below:
TERMINAL
Figur 6
WIRE
WIRE STOP
MATCH
UP MARKS
FRONT BACK
Figur 9

Hand Crimp Tool for 36P Robot Connector Plug and Receptacle Terminals
Doc No: ATS-63 239100 Release Date: 04-11-12 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 04-11-12
Figur 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITI
N
SETTING
WHEEL
RATCHET
RELEASE LEVER
1. The locator must be removed before reversing the tooling.
2. Remove the M3 BHCS which is holding the upper tooling.
3. Flip the upper tooling to the opposite side and replace the M3 BHCS.
Make sure the small markings on the front and back of the hand tool frame,
match up and are on the outside of the hand tool frame. See Figure and
9.
4. Do the same thing with the lower tooling and tighten the M3 screws. Be
sure the small markings line up.
5. Reinstall the locator by following the Instructions in the locator replacement
section.
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 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 pressing up
on the ratchet release lever in the
movable handle. See Figure 11.
How to Adjust Tool Pr load (S
Figur 12)
This hand tool is factory preset to 25-45
LBS. preload. It may be necessary over
the life of the tool to adjust tool handle
preload force. Listed below are the steps
required to adjust the crimping force of the hand tool to obtain proper crimp conditions:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figur 10
RATCHET RELEASE
LEVER
Figur 11

Hand Crimp Tool for 36P Robot Connector Plug and Receptacle Terminals
Doc No: ATS-63 239100 Release Date: 04-11-12 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 04-11-12
1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link
towards the top of the hand tool frame. This will release the preload adjustment wheel.
2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the setting wheel clockwise (CW).
3. Release the link to lock the setting wheel in place.
4. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.
Warranty
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: 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.
4. Use only the Molex terminals specified for crimping with this tool.
C rtification
Molex does not certify or re-certify 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.
% If the tool does not meet minimum pull force values, handle preload should be increased and the pull test
rerun, (See How to Adjust Preload).
% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.

Hand Crimp Tool for 36P Robot Connector Plug and Receptacle Terminals
Doc No: ATS-63 239100 Release Date: 04-11-12 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 04-11-12
RATCHET
RELEASE LEVER
2
Figur 13
1
3
PARTS LIST
It m Numb r Ord r Numb r D scription Quantity
REF 63 23-9100 Hand Crimp Tool Figure 13
1 63 23-9175 Locator Assembly 1
2 63 10-0104 Spring, Return 1
3 63 10-0105 Spring, Ratchet 1
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