Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
Modular Crimp Head
Order No. 63823-5470
FEATURES
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Application Tooling
Specification Sheet
TYPE 4A
Hand Crimp Tool
Order No. 63823-5400
A full cycle ratcheting hand tool ensures complete crimps
Ergonomically designed soft handles
Precisely designed crimping profiles with simple contact positioning
Easy handling due to outstanding force ratio
Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63813-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: 3.96mm (.156”) Pitch Wire-to-Wire and 6.50mm (.256”) Pitch Wire-to-Board Crimp Terminals,
20, 24, and 26 AWG.
Terminal
Series
50598
Terminal Order No.
Reel Form only
Wire Size
Insulation Diameter
Wire Strip Length
AWG mm
2
mm
In.
mm
In.
20
0.50
1.50-1.90
.059-.075
50598-8100
24
0.20
2.20-2.35
.087-.093
26
0.12
2.10-2.20
.083-.087
2.70-3.30 .106-.130
20
0.50
1.50-1.90
.059-.075
50600-8100
24
0.20
2.20-2.35
.087-.093
26
0.12
2.10-2.20
.083-.087
Customer to cut off terminal from reel: 0.25mm (.010”) maximum Cut-off Tab.
See crimp specification for the individual Insulation Diameter.
BEND UP
50600
DEFINITION OF TERMS
BELL MOUTH
BRUSH
INSULATION
CRIMP
▲SEE
NOTE
SEAM
ROLLING
STRIP
LENGTH
CUT-OFF TAB
CONDUCTOR
COND.CRIMP
CRIMP
HEIGHT
TWISTING
BEND
DOWN
This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.
Doc No: ATS-6382354HM
Revision: B
Release Date: 06-23-10
Revision Date: 10-13-10
UNCONTROLLED COPY
Page 1 of 6
Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
▲Insulation
Crimp Note:
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.
(Some tools with multiple crimp pockets may not have
the “overlap” profile on all pockets).
OVERLAP FORM GEOMETRY
PUNCH
OVERLAP
INSULATION
CRIMP
CRIMP SPECIFICATIONS:
Terminal
Series No
Wire Size
AWG mm
2
20
24
26
20
24
26
0.50
0.20
0.12
0.50
0.20
0.12
ANVIL
Pull Force
Minimum
N
58.84
29.42
14.71
58.84
29.42
14.71
Lb.
Profile
WIRE
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
mm
0.95-1.05
0.80-0.85
0.76-0.81
0.95-1.05
0.80-0.85
0.76-0.81
In.
.037-.041
.031-.034
.030-.032
.037-.041
.031-.034
.030-.032
Mm
1.60
1.60
1.60
1.60
1.60
1.60
In.
.063
.063
.063
.063
.063
.063
mm
2.30
2.50
2.00
2.30
2.50
2.00
In.
.091
.098
.079
.091
.098
.079
mm
2.20
2.60
2.60
2.20
2.60
2.60
In.
.087
.102
.102
.087
.102
.102
50598
50600
AWG AWG AWG
20
24
26
13.23 X
6.61
X
3.31
X
13.23 X
6.61
X
3.31
X
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.
Crimping Terminals
WIRE STOP BLADE
TERMINAL
INSULATION
PUNCH
WIRE STOP
BLADE
LOCATOR
CONDUCTOR
PUNCH
INSULATION
PUNCH
WIRE
TERMINAL
WIRE
Figure 1
CONDUCTOR ANVIL
INSULATION
ANVIL
1.
2.
3.
4.
Figure 2
Lift the wire stop blade up.
Insert the terminal fully into the correct profile until the terminal is fully seated and stops.
Bring down the wire stop blade.
Slide the pre-stripped wire into the wire stop blade. See Figure 1. Be sure to hold the wire in place until the
terminal is fully crimped. See Figure 2.
Doc No: ATS-6382354HM
Revision: B
Release Date: 06-23-10
Revision Date: 10-13-10
UNCONTROLLED COPY
Page 2 of 6
Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
5. Close the tool until the ratchet releases, the tool handles will then spring open.
6. Lift the wire stop blade up if it is still in down position.
7. Carefully remove the crimped terminal.
Note:
The tamper proof ratchet action will not release the tool until it has been fully closed.
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 lifting the ratchet release lever. See Figure 6.
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:
Repetitive use of this tool should be avoided.
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.
Doc No: ATS-6382354HM
Revision: B
Release Date: 06-23-10
Revision Date: 10-13-10
UNCONTROLLED COPY
Page 3 of 6
Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable for crimp height, however crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all
insulation sizes.
4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips
on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
6. Molex does not certify crimp hand tools.
CAUTION:
Molex crimp specifications are valid only when used with Molex terminals and tooling.
Applications for the Modular Crimp Head
WARNING:
NEVER
operate, service, install, or adjust this Modular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper Manual or Specification Sheet.
See Chart below for the correct Manual or Specification Sheet.
WARNING:
NEVER
install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging or turn off the Actuator from its power source.
CAUTION:
Keep fingers away from the crimping area when operating this tool. It may cause severe injury.
CAUTION:
Wear safety glasses when operating or serving this tool.
Doc No: ATS-6382354HM
Revision: B
Release Date: 06-23-10
Revision Date: 10-13-10
UNCONTROLLED COPY
Page 4 of 6
Hand Crimp Tool for Wire-to-Wire and Wire-to-Board Terminals
The chart below shows all applications for this Modular Crimp Head.
Modular Crimp Head
Order No.
Tool
Tool
Adapter
Adapter
Figure
Order no.
Description
Order No.
Description
No.
63816-0000 Hand Crimp Frame (Short)
N/A
N/A
3
63816-0050 Hand Crimp Frame (Long)
N/A
N/A
3
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter
4
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter
4
63816-0100
Air Power Tool
63816-0700
Air Power Crimp Adapter
5
63823-5470
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
Air Powered Tool
LOCKING
PINS
MODULAR
CRIMP
HEAD
LOCKING
PINS
LOCKING
PINS
MODULAR
CRIMP HEAD
AIR POWER
CRIMP
ADAPTER
LOCKING PINS
HAND CRIMP
FRAME LONG
OR SHORT
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
LOCKING
PINS
Figure 3
Figure 4
Figure 5
Doc No: ATS-6382354HM
Revision: B
Release Date: 06-23-10
Revision Date: 10-13-10
UNCONTROLLED COPY
Page 5 of 6
测试/测量
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