molex 63823-3900 User manual

Hand Crimp Tool for Splash Proof Crimp Terminal
Doc No: ATS-638233900 elease Date: 06-18-10 UNCONTROLLED COPY Page 1 of 7
evision: A evision Date: 06-18-10
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
Specification Sheet
Or er No. 63823-3900
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
 ight and Left handed applications
 This tool is oHS compliant, however oHS compliant is not required
SCOPE
Products: 2.50mm (.098") Pitch Splash Proof Crimp Terminal
Terminal Or er No. Wire Size Insulation Diameter Strip Length
Terminal Series No.
● Reel mm² mm In. mm In.
50038 (pin) ● 50038-8000 50038-8100 AVS 0.3 1.9 max .075 max 2.0 - 2.5 ..079 - .098
50039 (receptacle) ● 50039-8000 50039-8100 CAVS 0.5 1.9 max .075 max 2.0 - 2.5 ..079 - .098
● Customer to cut off terminal from reel: 0.3mm (.012”) 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 4D

Hand Crimp Tool for Splash Proof Crimp Terminal
Doc No: ATS-638233900 elease Date: 06-18-10 UNCONTROLLED COPY Page 2 of 7
evision: A evision Date: 06-18-10
TERMINAL
Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
LOCATOR
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Con uctor Crimp
Wire Size Height (Ref.) Wi th (Ref.) Profile
Terminal Series No.
mm2 mm In. mm In. 0.3 0.5
AVS 0.3 0.94 - 0.99 .037 - .039 1.4 .055 X 50038
pin
50039 receptacle CAVS 0.5
0.96 - 1.06 .038 - .042 1.4 .055 X
Wire Size Insulation Crimp
Height (Ref.) Wi th (Ref.)
Pull Force
Minimum
Terminal Series No.
mm2 mm In. mm In. N Lb.
AVS 0.3 2.0 max .079 max 1.8 .071 49 11 50038 pin
50039 receptacle CAVS 0.5 2.0 max .079 max 1.8 .071 53.9 12.1
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
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.
Crimping Terminals
1. Select the desired terminal listed in
the preceding charts. 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.
LOCATOR IN
DOWN POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1

Hand Crimp Tool for Splash Proof Crimp Terminal
Doc No: ATS-638233900 elease Date: 06-18-10 UNCONTROLLED COPY Page 3 of 7
evision: A evision Date: 06-18-10
Figure 5 TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF THE
LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
2. 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.
3. elease the locator button, allowing the locator to return to the crimping
position.
4. Close the tool handle until the first ratchet position engages. See
Figure 4.
5. Insert the properly stripped wire through the terminal and against the
wire stop. See Figure 5.
6. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. elease the handles to open
the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
7. emove the crimped terminal from the terminal
locator by pulling on the wire.
8. Visually inspect the crimped terminal for proper
crimp location.
9. 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.
Note:
A crimp height chart is provided with this manual as eference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers 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 specifications listed.
TERMINAL
Figure 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool for Splash Proof Crimp Terminal
Doc No: ATS-638233900 elease Date: 06-18-10 UNCONTROLLED COPY Page 4 of 7
evision: A evision Date: 06-18-10
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
Locator Replacement
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. otate 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 Left Han Operation
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:
1. The locator must be removed before reversing the
tooling.
2. emove 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 8 and 9.
4. Do the same thing with the lower tooling and
tighten the M3 screws. Be sure the small
markings line up.
5. einstall the locator by following the Instructions
in the locator replacement section.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MATCH
UP MARKS
FRONT BACK
Figure 9

Hand Crimp Tool for Splash Proof Crimp Terminal
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evision: A evision Date: 06-18-10
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POITION
ADJUSTING
WHEEL
RATCHET
RELEASE LEVER
Maintenance
It is recommended that each operator of the tool be made aware of, and
responsible for, the following maintenance steps:
1. emove 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 A just Tool Preloa (See
Figure 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:
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. otate 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).
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11

Hand Crimp Tool for Splash Proof Crimp Terminal
Doc No: ATS-638233900 elease Date: 06-18-10 UNCONTROLLED COPY Page 6 of 7
evision: A evision Date: 06-18-10
3. elease 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. epetitive 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.
Certification
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 Splash Proof Crimp Terminal
Doc No: ATS-638233900 elease Date: 06-18-10 UNCONTROLLED COPY Page 7 of 7
evision: A evision Date: 06-18-10
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Or er Number Description Quantity
EF 63823-3900 Hand Crimp Tool Figure 13
1 63823-3975 Locator Assembly 1
2 63810-0104 Spring, eturn 1
3 63810-0105 Spring, atchet 1
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63810-0105