Molex 63823-9100 Bedienungsanleitung

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

1 0.90 1.21 – 1.31

.04 – .052

19 0.75 1.1 – 1.2

.046 – .050

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

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

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

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

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

Figur 13

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

http://www.molex.com

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