molex 63823-5600 User manual

Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals
Doc No ATS-638235600 Release Date 03-08-10 UNCONTROLLED COPY Page 1 of 7
Revision A Revision Date 03-08-10
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. 63823-5600
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 and Left handed applications
 This tool is IPC/WHMA A-620 Class 2 compliant
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products 2.00mm (.079") Pitch Male Crimp Terminals, 14 - 18 AWG.
Terminal Or er No. Wire Size an Type Insulation Diameter (Maximum Strip Length Terminal
Series No.
Loose Reel AWG mm² mm In. mm In.
50638-9128 50638-9028
50638 50638-9149
50638-9049
14 - 18 2.21- 0.81 3.80 .150 3.90 – 4.40 .154-.173
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 2.00mm (.079") Pitch Male Crimp Terminals
Doc No ATS-638235600 Release Date 03-08-10 UNCONTROLLED COPY Page 2 of 7
Revision A Revision Date 03-08-10
RELEASE
LOCATOR BUTTON
TERMINAL
Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
Fig3
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Con uctor Crimp Insulation Crimp
Wire Size Height (Ref.) Wi th (Ref.)
Height (Ref.) Wi th (Ref.)
Pull Force
Minimum Profile
Terminal
Series No.
AWG mm2 mm In. mm In. mm In. mm In. N Lb. 16 18 14
14 2.21 1.59 - 1.69 .063-.067 2.60 .102 4.00 .157 4.00 .157 147.0 33.0 X
16 1.31 1.39 - 1.49 .055-.059 2.60 .102 3.90 .154 4.00 .157 127.0 28.5 X
50638
18 0.81 1.22 - 1.32 .048-.052 2.60 .102 3.70 .146 4.00 .157 88.2 19.8 X
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.
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.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1

Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals
Doc No ATS-638235600 Release Date 03-08-10 UNCONTROLLED COPY Page 3 of 7
Revision A Revision Date 03-08-10
PRE-STRIPPED WIRE
TERMINAL
WIRE AGAINST THE
WIRE STOP
Figure 5
TERMINAL
WIRE
WIRE STOP IS PART
OF THE LOCATOR
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.
8. 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.
TERMINAL
Figure 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals
Doc No ATS-638235600 Release Date 03-08-10 UNCONTROLLED COPY Page 4 of 7
Revision A Revision Date 03-08-10
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
Note:
A crimp height chart is provided with this manual as Reference 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.
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. 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 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. 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 8 and 9.
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B

Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals
Doc No ATS-638235600 Release Date 03-08-10 UNCONTROLLED COPY Page 5 of 7
Revision A Revision Date 03-08-10
MATCH
UP MARKS
FRONT BACK
Figure 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.
Maintenance
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 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11

Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals
Doc No ATS-638235600 Release Date 03-08-10 UNCONTROLLED COPY Page 6 of 7
Revision A Revision Date 03-08-10
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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.
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 2.00mm (.079") Pitch Male Crimp Terminals
Doc No ATS-638235600 Release Date 03-08-10 UNCONTROLLED COPY Page 7 of 7
Revision A Revision Date 03-08-10
2
Figure 13
1
3
PARTS LIST
Item Number Or er Number Description Quantity
REF 63823-5600 Hand Crimp Tool Figure 13
1 63823-5675 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
Americas Hea quarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
[email protected]
Far East North Hea quarters
Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
Far East South Hea quarters
Jurong, Singapore
65-6-268-6868
[email protected]
European Hea quarters
Munich, Germany
49-89-413092-0
[email protected]
Corporate Hea quarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax [phone]
Visit our Web site at http://www.molex.com