Molex 63811-9200 Manuale utente

Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals

Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 1 of 6

Revision: E Revision Date: 01 28 10

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

HAND CRIMP TOOL

SPECIFICATION SHEET

Order No. 63811- 200

FEATURES

 A full cycle ratcheting hand tool ensures complete crimps

 A precision user friendly terminal locator wire stop holds terminals in the proper crimping position

 This tool is WHMA IPCA620 Class 3 only with specified wire types and RoHS compliant

SCOPE

Products: 0.60mm (.027") CP0.6 Female Crimp Terminals for CMC connector 18 20 AWG and 0.50 0.75mm2.

Terminal Order No. Wire Size Insulation Diameter Strip Length

Terminal Series No. 



Available in Reel form only AWG mm² mm In. mm In.

18 1.91 2.06 .075 .081 3.50 .138

0.75 1.60 1.80 .063 .071 3.50 .138

0.60 1.75 1.90 .069 .075 3.50 .138

20 1.70 1.85 .067 .073 3.50 .138

98913 64322

98913 1029

98913 1219

98913 1319

98913 1339

98913 1039

98913 1239

98913 1359

64322 1029

64322 1219

64322 1319

64322 1339

64322 1039

64322 1239

64322 1359 0.50 1.40 1.50 .055 .059 3.50 .138

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

Note: Terminal will accommodate the thin wall small insulation with the TXL type American wires

and the IR or ID type Metric wires.

DEFINITION OF TERMS

TYPE 7

Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals

Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 2 of 6

Revision: E Revision Date: 01 28 10

CRIMP SPECIFICATION

After crimping, the conductor profiles should measure the following (see notes on page 5).

Conductor Crimp Insulation Crimp

Wire Size Height (Ref.) Height (Ref.)

Pull Force

Minimum Profile

Terminal Series No.

AWG

mm2 mm In. mm In. N Lb. 18-20 AWG

0.6-0.75 0.50

18 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25

0.75 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25

0.60 1.00 1.06 .039 .042 1.80 1.95 .071 .077 80.0 18.00

20 1.00 1.06 .039 .042 1.80 1.95 .071 .077 75.0 16.90

98913

0.50 0.97 1.03 .038 .040 1.70 1.85 .067 .073 70.0 15.75

18 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25

0.75 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25

0.60 1.00 1.06 .039 .042 1.80 1.95 .071 .077 80.0 18.00

20 1.00 1.06 .039 .042 1.80 1.95 .071 .077 75.0 16.90

64322

0.50 0.97 1.03 .038 .040 1.70 1.85 .067 .073 70.0 15.75

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.

Crimping Terminals

1. Select the desired terminal listed in the preceding charts.

2. Position the terminal from the back of the hand tool up and

into the proper locator opening with the crimp barrels

centered over the anvils. See Figure 1. Make sure when

choosing the correct nest and locator opening, it will

correspond with the pocket marked with the wire size

profile on the hand tool.

3. Partially close the jaws of the hand tool by squeezing the

handles until you hear the fist click of the ratchet. This will

move the wire stop into position.

4. From the front of the hand tool insert the pre stripped wire

over the terminal and against the wire stop. See Figure 2.

5. Compress the terminal by squeezing the tool handles until

the ratchet mechanism cycle has been completed. Release handles to open the jaws.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Figure 1 LOCATOR

WIRE STOP

TERMINAL INSIDE

THE GROOVE

OF THE LOCATOR

BACK OF THE

HANDTOOL

Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals

Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 3 of 6

Revision: E Revision Date: 01 28 10

6. Remove the crimped terminal from the terminal locator.

7. Visually inspect the crimped terminal for proper crimp

location.

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, 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.

Maintenance

It is recommended that each operator of the tool be made aware of, and responsible for, the following

maintenance steps:

1. Remove the plastic handles from the metal tool frame by

removing the screws and 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

fine piece of equipment it needs cleaning and lubrication for a

maximum service life of trouble free crimping. Light oil used at

the pivot 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.

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 the ratchet release lever up. See Figure 3.

WIRE

Figure 2

WIRE IS UP AGAINST

THE WIRE STOP

FRONT OF THE

HAND TOOL

TERMINAL

RATCHET

RELEASE LEVER

Figure 3

Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals

Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 4 of 6

Revision: E Revision Date: 01 28 10

NUMBERED ADJUSTMENT

WHEEL

Figure 4

TURN CLOCKWISE (CW) OR

COUNTER CLOCKWISE (CCW)

TO ADJUST THE PRE-LOAD

TURN WITH A SMALL

SCREW DRIVER

REMOVE THE LOCKING 2MM SCREW

How to Adjust Tool 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. Remove the 2mm locking screw from the numbered adjusting wheel using a screw driver. See Figure 4.

2. Using the same screw driver turn the adjustment wheel to the next highest number.

Note: The uneven numbers are in clockwise (CW) direction and the even numbers are counter clockwise

(CCW).

3. Example: If the preload is set at number 5, then to increase the preload, turn the adjustment wheel until the 6th

position is located over the 2mm locking screw tapped hole. If it is necessary to move to the 7th position, then

the adjustment wheel should be turned counter clockwise (CCW) until the 7th position is over the 2mm locking

screw tapped hole.

4. Replace the 2mm locking screw, aligning the nearest notch in the setting wheel to locking screw.

5. Check the crimp specifications and conduct a pull test after tool handle preload force is adjusted. Repeat these

steps until the desired result is obtained.

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.

Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals

Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 5 of 6

Revision: E Revision Date: 01 28 10

CAUTIONS:

1. Manually powered hand tools are intended for low volume, prototyping, 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 0.60mm (.027") CP 0.6 Series Crimp Terminals

Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 6 of 6

Revision: E Revision Date: 01 28 10

Figure 5

M3 X 6LG

BHCS

PARTS LIST

Item Number Order Number Description Quantity

REF 63811- 200 Hand Crimp Tool Figure 5

1 63811 9275 Locator 1

2 11 11 0320 Spring (Ratchet) 1

3 63600 0479 Spring (Main) 1

4 69008 0972 Adjuster Wheel 1

Americas Headquarters

Lisle, Illinois 60532 U.S.A.

1 800 78MOLEX

[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

[email protected]

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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