63811-8000 Spec Sheet Datasheet by Molex

Hand Cnmp Tool for 2.50mm (.098“) thch Cnmp Termmals Producb CRIMP HEIGHT

Hand Crimp Tool for 2.50mm (.098") Pitch Crimp Terminals

Doc No: ATS-638118000 Release Date: 07-13-07 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 07-13-07

HAND CRIMP TOOL

Specification Sheet

Order No. 63811-8000

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 WHMA-IPCA620 Class 2 compliant

This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: 2.50mm (.098") Pitch Crimp Terminal, 22-28 AWG.

Terminal Order No. Wire Size Insulation Diameter Strip Length Terminal

Series No. Loose Piece Reel AWG mm² mm In. mm In.

39-00-0031 39-00-0023

39-00-0364

39-00-0412

5479

39-00-0417

22-28 0.33-0.08 1.20-1.80 .047-.071 1.20-2.20 .047-.087

Follow the Cut-Off Tab specifications on Applicator specification sheets.

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

TYPE 4D

.098“) thch Cnmp Termmals ( Hand Cnmp Tool for 2.50mm

Hand Crimp Tool for 2.50mm (.098") Pitch Crimp Terminals

Doc No: ATS-638118000 Release Date: 07-13-07 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 07-13-07

TERMINAL Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

RELEASE

LOCATOR

BUTTON

LOCATOR

BUTTON

PUSHED IN

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Conductor Crimp Insulation Crimp

Wire Size Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Pull Force

Minimum Profile

Terminal Series No AWG mm2 mm In. mm In. mm In. mm In. N Lb. 22-24 26-28

22 0.33 0.72-0.82 .028-.032 1.41 .055 1.67 .065 1.78 .070 39.2 8.82 X

24 0.20 0.72-0.82 .028-.032 1.41 .055 1.67 .065 1.78 .070 29.4 6.61 X

26 0.12 0.62-0.72 .024-.028 1.43 .056 1.39 .055 1.39 .055 19.6 4.41 X

5479

28 0.08 0.62-0.72 .024-.028 1.43 .056 1.39 .055 1.39 .055 9.8 2.20 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.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure

LOCATOR IN

DOWN POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

Hand Cnmp Tool for 2.50mm (.098“) thch Cnmp Termmals W

Hand Crimp Tool for 2.50mm (.098") Pitch Crimp Terminals

Doc No: ATS-638118000 Release Date: 07-13-07 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 07-13-07

Figure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS

PART OF

THE LOCATOR

PRE-STRIPPED

WIRE

TERMINAL

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 Cnmp Tool for 2.50mm (.098“) thch Cnmp Termmals Reference On‘y. Z r: r,

Hand Crimp Tool for 2.50mm (.098") Pitch Crimp Terminals

Doc No: ATS-638118000 Release Date: 07-13-07 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 07-13-07

Figure 11

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

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 preformed 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 the frame.

Right or Left Hand 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:

SQUEEZE

HERE

LOCATOR

Figure 7A

SQUEEZE

HERE

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

MATCH

UP MARKS

FRONT BACK

Figure 12

Hand Cnmp Tool for 2.50mm (.098“) thch Cnmp Termmals

Hand Crimp Tool for 2.50mm (.098") Pitch Crimp Terminals

Doc No: ATS-638118000 Release Date: 07-13-07 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 07-13-07

1. The locator must be removing 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

11 and 12.

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

How to Adjust Tool Preload (See Figure 10)

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. 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).

RATCHET RELEASE

LEVER

Figure 9

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 8

Hand Cnmp Tool for 2.50mm (.098“) thch Cnmp Termmals CAUTIONS:

Hand Crimp Tool for 2.50mm (.098") Pitch Crimp Terminals

Doc No: ATS-638118000 Release Date: 07-13-07 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 07-13-07

Figure 10

SQUEEZE

THE LINK IN

THE HANDLE HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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 Cnmp Tool for 2.50mm (.098“) thch Cnmp Termmals Item Number Order Number Description Quantity

Hand Crimp Tool for 2.50mm (.098") Pitch Crimp Terminals

Doc No: ATS-638118000 Release Date: 07-13-07 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 07-13-07

RATCHET

RELEASE LEVER

Figure 13

PARTS LIST

Item Number Order Number Description Quantity

REF 63811-8000 Hand Crimp Tool Figure 13

1 63811-8075 Locator Assembly 1

2 63810-0104 Spring, Return 1

3 63810-0105 Spring, Ratchet 1

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Lisle, IL 60532 U.S.A.

630-969-4550

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