Molex 63811-8300 Manuale utente

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 1 of 10

Revision: A Revision Date: 05-16-07

INSULATIO

CRIMP

BRUS

STRIP

LENGTH

BELL

MOUTH

CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLIN

CONDUCTO

CRIMP

TWISTING

HAND CRIMP TOOL

Specification Sheet

Order No. 63811-8300

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 as indicated

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

SCOPE

Products: 3.50mm (.138") Pitch Crimp Terminal, 18-24 AWG UL1015 and UL1007 or

equivalent.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

Loose Piece

Reel

AWG

mm²

In.

50217

50217-8100

50217-8000

18-24

0.80-0.20

1.40-3.00

.055-.118

3.00-3.50

.118-.138

50217-9101

50217-9001

50539

50539-8100

50539-8000

18-24

0.80-0.20

1.40-3.00

.055-.118

3.00-3.50

.118-.138

50539-9101

50539-9001

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

See Conditions on page 2.

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 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 2 of 10

Revision: A Revision Date: 05-16-07

CONDITIONS:

After crimping, the conductor profiles should measure the following.

Terminal Series No

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Profile

Height (Ref.)

Width

(Ref.)

Height (Ref.)

Width

(Ref.)

AWG

mm2

In.

Lb.

18-20

22-24

50217

0.80

1.02-1.12

.040-.044

1.80

.071

2.63

.103

2.82

.111

89.0

20.0

0.50

1.02-1.12

.040-.044

1.80

.071

2.63

.103

2.82

.111

57.9

13.0

0.35

0.87-0.97

.034-.038

1.93

.076

2.45

.096

2.30

.090

35.6

8.0

0.20

0.87-0.97

.034-.038

1.93

.076

2.45

.096

2.30

.090

22.3

5.0

50539

0.80

1.02-1.12

.040-.044

1.80

.071

2.63

.103

2.82

.111

89.0

20.0

0.50

1.02-1.12

.040-.044

1.80

.071

2.63

.103

2.82

.111

57.9

13.0

0.35

0.87-0.97

.034-.038

1.93

.076

2.45

.096

2.30

.090

35.6

8.0

0.20

0.87-0.97

.034-.038

1.93

.076

2.45

.096

2.30

.090

22.3

5.0

To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:

Profile 18-20: 3.00-1.75mm (.118-.069 inch)

Profile 22-24: 2.30-1.40mm (.090-.058 inch)

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.

4. Release the locator button, allowing the locator to return to the crimping position.

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR IN

DOWN

POSTION

PUSH ON THE

LOCATOR

BUTTON

Figure 2

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 3 of 10

Revision: A Revision Date: 05-16-07

TERMINAL

Figure 3

LOCATOR

PUSHED

THRU

TOOLING

TERMINAL

RELEASE

LOCATOR

BUTTON

LOCATOR

BUTTON

PUSHED IN

Figure 5

TERMINAL

WIRE AGAINST

THE WIRE

STOP

WIRE

WIRE STOP IS PART

THE LOCATOR

PRE-

STRIPPED

WIRE

TERMINAL

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

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

TERMINAL

Figure 6

WIRE

STOP

PARTIALLY

HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST

RATCHET

POSITION

OPEN

POSITIO

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 4 of 10

Revision: A Revision Date: 05-16-07

preformed to check hand tool crimp. Pull Force value Must exceed the Minimum pull force

specifications listed.

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 5 of 10

Revision: A Revision Date: 05-16-07

MATCH

UP MARKS

FRONT

BACK

Figure 12

Figure

PUSH ON

HANDLE

JAWS OPEN

PULL

OPEN

TOOLING

M3 BHCS

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:

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.

SQUEEZ

HERE

LOCATOR

Figure 7A

SQUEEZ

HERE

TOP

HOOKS

TOP SLOTS

HANDTOOL

LOWER

TABS

MAKE SURE

CENTER OF

LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 6 of 10

Revision: A Revision Date: 05-16-07

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.

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 7 of 10

Revision: A Revision Date: 05-16-07

Figure 10

SQUEEZE

THE LINK IN

THE

HANDLE

HOLD THE

HAND

TOOL IN

POSITION

SETTING

WHEEL

RATCHET

RELEASE

LEVER

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 9.

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

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY 3 MONTHS

5,000 CRIMPS)

Figure 8

RATCHET

RELEASE

LEVER

Figure 9

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 8 of 10

Revision: A Revision Date: 05-16-07

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.

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 9 of 10

Revision: A Revision Date: 05-16-07

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 3.50mm (.138") Pitch Crimp Terminals

Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED

COPY Page 10 of 10

Revision: A Revision Date: 05-16-07

RATCHET

RELEASE

LEVER

Figure

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63811-8300

Hand Crimp Tool

Figure 13

63811-8375

Locator Assembly

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

Americas Headquarters

Lisle, Illinois 60532 U.S.A.

1-800-78MOLEX

amerinf[email protected]

Far East North Headquarters

Yamato, Kanagawa, Japan

81-462-65-2324

[email protected]

Far East South Headquarters

Jurong, Singapore

65-6-268-6868

fesinfo@molex.com

European Headquarters

Munich, Germany

49-89-413092-0

[email protected]

Corporate Headquarters

2222 Wellington Ct.

Lisle, IL 60532 U.S.A.

630-969-4550

Fax: 630-969-1352

Visit our Web site at http://www.molex.com

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