hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 1 of 8 revision: c revision date: 01-03-12 conductor brush strip length seam conductor crimp cut-off tab bell mouth bend up twisting rolling bend down wire application tooling specification sheet tool kit order no. 63823-6470 hand crimp tool order no. 63823-6400 features % a full cycle ratcheting hand tool ensures complete crimps % ergonomically designed soft handles % precisely designed crimping profiles with simple co ntact positioning % easy handling due to outstanding force ratio tool kits are easily installed into the hand crimp tool or the 63816-0300 power crimp head which is in stalled into the 63816-0200 (110 v) or the 63816-0250 (220 v) battery powered tool. many different tool kits can be used with a single battery powered tool. this tool is ipc/whma-a-620 class 2 and rohs compli ant. scope products : pv solar pin and socket crimp terminals, 10-14 a wg (6.0-2.5mm2) terminal series no. terminal order no. wire size and type insulation di ameter (ref) strip length loose reel only awg mm2 mm in. mm in. 130196 130196-0310 130196-0314 10-12 6.00-4.00 7.8 .31 7.00-10.00 .276-.394 130196-0313 130196-0315 14 2.50 6.7 .26 7.00-10.00 .276-.394 130197 130197-0325 130197-0346 10-12 6.00-4.00 7.8 .31 7.00-10.00 .276-.394 130197-0336 130197-0347 14 2.50 6.7 .26 7.00-10.00 .276-.394 93302 93302-0006 93302-0004 10-12 6.00-4.00 7.8 .31 7.00-10.00 .276-.394 93302-0005 93302-0003 14 2.50 6.7 .26 7.00-10.00 .276-.394 93303 93303-0005 93303-0003 10-12 6.00-4.00 7.8 .31 7.00-10.00 .276-.394 93303-0006 93303-0004 14 2.50 6.7 .26 7.00-10.00 .276-.394 customer to cut off terminal from reel: 0.50mm (.02 0) maximum cut-off tab. definition of terms the above terminal drawing is a generic terminal re presentation. it is not an image of a terminal lis ted in the scope. type 4c
hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 2 of 8 revision: c revision date: 01-03-12 conditions: terminal series no. wire size bell mouth cut-off tab maximum conductor brush awg mm2 mm in. mm in. mm in. 130196 and 93302 10-14 6.00-2.50 0.20-1.50 .008-.05 9 0.50 .020 1.00-3.00 .039-.118 130197 and 93303 10-14 6.00-2.50 0.20-1.50 .008-.05 9 0.50 .020 1.00-3.00 .039-.118 terminal series no. wire size bend up bend down twist roll punch width (ref) seam seam shall not be open and no wire allowed out of the crimping area conductor awg mm 2 degree degree mm in 130196 and 93302 10-12 6.00-4.00 3 3 4 8 3.90 .154 14 2.50 3 3 4 8 2.90 .114 130197 and 93303 10-12 6.00-4.00 3 3 4 8 3.90 .154 14 2.50 3 3 4 8 2.90 .114 after crimping, the conductor profile should measur e the following. terminal series no. wire size conductor crimp height pull force minimum awg mm 2 mm in. n lb. 130196 and 93302 10 6.00 2.10-2.20 .083-.087 356.0 80.0 12 4.00 2.00-2.10 .079-.083 312.0 70.0 14 2.50 1.60-1.70 .063-.067 223.0 50.0 130197 and 93303 10 6.00 2.10-2.20 .083-.087 356.0 80.0 12 4.00 2.00-2.10 .079-.083 312.0 70.0 14 2.50 1.60-1.70 .063-.067 223.0 50.0 the above specifications are guidelines to an optim um crimp. note: a crimp height chart is provided with this manual a s reference only. due to the wide range of wires and stranding, actual crimp height measurements may very slightly. an occasional, destructive, pull force test shoul d be preformed to check hand tool crimp. pull force val ue must exceed the minimum pull force specifications liste d. caution: install only molex terminals listed above with this tool. do not crimp hardened objects as damage can occur to the tool or die. installation to install the tool kit into the power crimp head f ollow the steps below: anvil and punch installation 1. insert the anvil into the bottom slots of the nest. install the m4 x 10 long bhcs and tighten in plac e. 2. insert the punch into the top slots of the nest. i nstall the m4 x 18 long bhcs and tighten in place. see figure 1. locator installation and removal follow the steps below to install or replace the lo cator. see figure 2. to install the locator 1. position the locator with the hole over the brass p ivot shaft and snap it into place.
hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 3 of 8 revision: c revision date: 01-03-12 swing locator open press down on the brass pivot shaft lift up on the locator figure 2 anvil power crimp head figure 1 punch m4 x 10mm long bhcs m4 x 18mm long bhcs swing open terminal push here to open wire stop locator terminal in place figure 4 locator latch in open position to remove the locator 1. open the crimp hand tool. 2. swing the existing locator open and away from the h and tool. 3. firmly press down on the brass pivot shaft with you r thumb, while pulling the locator up. slip the lo cator off the top of the brass pivot shaft. operation open the tool by squeezing the handles together, at the end of the closing stroke, the ratchet mechanism wi ll release the handles, and the hand tool will spring open. crimping terminals 1. select the desired terminal listed in the preceding charts. 2. turn the locator lock latch down to unlock. see figure 3. figure 3 latch locked latch unlocked
hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 4 of 8 revision: c revision date: 01-03-12 figure 6 wire in terminal jaws partially closed wire against wire stop handle open locator closed figure 5 terminal push here to open wire stop 3. swing the terminal locator away from the crimp tool shown in figure 4. some terminals with large cond uctor grips may interfere with the crimp tooling when swi nging the locator into position. the terminal must then be loaded into the locator in the closed/crimp positio n. see figure 5. 4. press down on the wire stop on the locator as shown in figure1. insert the proper terminal into the p roper nest opening. make sure when choosing the nest opening, it will correspond with the 10, 12 or 14 profile o n the hand tool. 5. return the locator to its original position. 6. turn the locator lock latch up to lock. make sure that the terminal is visually centered over the punch. 7. insert the proper wire over the terminal. 8. gently touch the wire stop with the end of the wire. see figure 6 and 7. 9. crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. release handles to open the jaws. 10. remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on the wire. 11. visually inspect the crimped terminal for proper crimp location. note : the tamper proof ratchet action will not release the tool until it has been fully closed. for the battery power tool: 1. cycle the battery power tool to crimp the terminal to the wire. 2. remove the crimped terminal from the terminal locat or by pressing down on the wire stop and gently pul ling on the wire. 3. visually inspect the crimped terminal for proper cr imp location. figure 7 wire conductor anvil locator wires against locator stop conductor punch terminal
hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 5 of 8 revision: c revision date: 01-03-12 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 in the tool head are protected with a thin coat of high quality machine oil. do not oil excessively. this tool was engineered for durability, but like any fi ne piece of equipment, it needs cleaning and lubric ation for a maximum service life of trouble-free crimping. the use of light oil, such as 30 weight automotive oil , every 5,000 crimps or monthly, will significantly enhance the tool life and ensure a stable calibration. se e figure 8a or 8b for lubrication points. 4. store the tool in a clean and dry area when not in use. miscrimps or jams for crimp hand tools only (see figure 11) should this tool ever become stuck or jammed in a p artially closed position, do not force the handles open or closed. the tool will open easily by rotating the small s lotted screw marked with an arrow. see figure 11. warranty this tool kit is for electrical terminal crimping p urposes only. this tool kit is made of the best qu ality materials. all vital components are long life tested. all tools a re warranted to be free of manufacturing defects fo r a period of 30 days. should such a defect occur, we will repair o r exchange the tool kit free of charge. this repai r or exchange will not be applicable to altered, misused, or dama ged tools. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling. cautions 1. manually powered hand tools are intended for low vo lume 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. caution: repetitive use of this tool should be avoided. lubrication points (both sides) light oil (every month or 5,000 crimps) figure8a figure 8b
hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 6 of 8 revision: c revision date: 01-03-12 certification molex does not certify or re-certify commercial gra de hand tools but rather supplies the following gui delines for customers to re-certify hand tools. % this tool is qualified to pull force only. to re-c ertify, 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 n o faster than 25mm (1.00) per minute. see the molex web site fo r the quality crimp handbook for more information o n pull testing. % when the hand tool is no longer capable of achievin g minimum pull force, it should be taken out of ser vice and replaced. % this tool is very difficult to disassemble and reas semble. customer repair is not recommended. the chart below shows all applications for this too l kit. tool kit order no. tool order no. tool description power head order no. adapter description figure no. 63823-6470 63810-1000 hand crimp frame (long) n/a n/a 9 63816-0200 battery power tool (110 v) 63816-0300 power crimp head 10 63816-0250 battery power tool (220 v) 63816-0300 power crimp head 10 applications for the tool kit hand crimp tool battery powered tool figure 9 figure 10 warning : never operate service, install tool kits, or adjust the p ower crimp head without proper instruction and without first reading and understan ding the instructions in the proper manual or specification sheet. see chart above for the corre ct manual or specification sheet. warning : never install tooling or service this tool while it is co nnected to any power source. make sure the power is disconnected. caution: to prevent injury, keep fingers away from the crimp ing area when operating this tool. caution: wear safety glasses when operating or servicing thi s tool. power crimp head locking pins battery powered tool tooling kit hand crimp frame long and short tooling kit
hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 7 of 8 revision: c revision date: 01-03-12 ratchet release screw figure 11 m4 x 8mm long bhcs 2 1 1 m4 x 18mm long bhcs m4 x 10mm long bhcs 2 3 with tool kit locator only hand tool parts list item number order number description quantity 1 63810 - 1000 hand crimp frame (long) 1 2 63823-6470 tool kit with locator 1 3 63823-6475 locator (only) ref
hand tool for pv solar pin and socket crimp termina ls doc no: ats-6382364hm release date: 03-04-11 uncontrolled copy page 8 of 8 revision: c revision date: 01-03-12 figure 12 1 2 2 m4 by 8mm long bhcs m4 by 18mm long bhcs m4 by 10mm long bhcs 1 power head parts list item order no engineering no. description quantity 1 63816-0300 63816-0300 power crimp head 1 2 63823-6470 63823-6470 tool kit 1 http://www.molex.com
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