Molex 63811-4700 Bedienungsanleitung

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05

UNCONTROLLED COPY

Page 1 of 8

Revision: B Revision Date: 0 -24-1

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP

CUT

OFF

TAB

BELL MOUTH

BEND

TWISTING

ROLLING

BEND

DOWN

WIRE

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63811-4770

Hand Crimp Tool

Ord r No. 63811-4700

FEATURES

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

Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head, which is installed

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 compliant

SCOPE

Products: MLX Crimp Terminals, 10-12 AWG.

T rminal S ri s No.

T rminal Ord r No.

Wir Siz

Insulation Diam t r

Strip L ngth



R l

Loos

AWG

mm²

In.

36663

0001

36663

0002

5.00

3.30

(1)

6.40

.14

.252

.281

36664

0001

36664

0002

5.00

3.30

(1)

6.40

.14

.252

.281



Customer to

off

terminal from reel

: 0.50mm (.020”) maximum

off

ab.

(1)This terminal series does not have an insulation crimp

DEFINITION OF TERMS

TYPE 4C

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 2 of 8

Revision: B Revision Date: 0 -24-1

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figur

ANVILS

POWER

CRIMP

HEAD

Figur

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

CONDITIONS

After crimping, the conductor profiles should measure the following (See notes below):

T rminal S ri s No. Wir Siz

Conductor Crimp

Pull Forc

Minimum Profil

H ight

Conductor Width

AWG

In.

Lb.

A B

36663

5.0

2.35

2.45

.093

.095

3.50

3.60

.138

.142

355.9

80.0

3.3

1.90

2.00

.0 5

.0 8

3.50

3.60

.138

.142

311.4

0.0

36664

5.0

2.35

2.45

.093

.095

3.50

3.60

.138

.142

355.9

80.0

3.3

1.90

2.00

.0 5

.0 8

3.50

3.60

.138

.142

311.4

0.0

Tool Qualification Not s

1. Pull force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

Not

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 performed to check hand tool crimp. Pull force value must exceed the minimum

pull force specifications listed.

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, follow the steps below:

Anvils and Punch s Installation

1. Insert the anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.

2. Insert the punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See

Figure 1.

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 3 of 8

Revision: B Revision Date: 0 -24-1

Locator Installation and R moval

Follow the steps below to install or replace the locator. See

Figure 2.

To install th locator

1. Position the locator with the hole over the brass pivot

shaft, and snap it into place.

To r mov th locator

1. Open the crimp hand tool.

2. Swing the existing locator open and away from the

hand tool.

3. Firmly press down on the brass pivot shaft with your thumb while pulling the locator up. Slip the locator off of

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 will

release the handles, and the hand tool will spring open.

Crimping T rminals

Swing the terminal locator against the crimp tool, and turn the lock up to lock the locator. Terminals can be loaded

easily while the locator is against the crimp tool and locked. The spring-loaded locator needs to be in the up

position for terminals to load easily.

1. To raise the wire stop, press the tab on the wire stop as shown in Figure 3. Insert the proper terminal into the

nest opening, and release the wire stop to lower it. Make sure when choosing the nest opening that it will

correspond with the A or B profile on the hand tool.

2. Insert the proper pre-striped wire over the terminal. Gently touch the wire stop with the end of the wire. See

Figures 4 and 5.

3. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

HANDLE

OPEN

LOCK IN

UP RIGHT

POSITION

LOCATOR

CLOSED

Figur 3

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

Figur 4

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

LOCATOR ANVIL

TERMINAL

WIRE

PUNCH

WIRE AGAINST STOP

Figur 5

WIRE STOP

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 4 of 8

Revision: B Revision Date: 0 -24-1

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

4. Remove the crimped terminal from the terminal locator by pressing the tab on the wire stop and gently pulling

on the wire.

5. Visually inspect the crimped terminal for proper crimp location and crimp height.

For th Batt ry Pow r Tool:

1. Cycle the Battery Power Tool to crimp the terminal to the wire.

2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire. The terminal locator can be in either position.

3. Visually inspect the crimped terminal for proper crimp location.

Maint nanc

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 a 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 fine piece of equipment, it needs

cleaning and lubrication for a maximum

service life of trouble-free crimping. The

use of a 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. See Figure 6A or 6B 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

(S Figur 9)

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 rotating the small slotted screw marked with an arrow. See Figure 9.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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, Molex will repair or exchange the tool kit free of charge. This repair or exchange

will not be applicable to altered, misused or damaged tools.

Figur 6B

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figur 6

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 5 of 8

Revision: B Revision Date: 0 -24-1

Handheld crimping tools are intended for low-volume use, prototyping or repair requirements only.

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 use 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.

C rtification

Molex does not certify or re-certify commercial grade 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. mm (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 website for the Quality Crimp Handbook for more information on pull

testing.

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 6 of 8

Revision: B Revision Date: 0 -24-1

The chart below shows all applications for this Tool Kit.

Tool Kit

Ord r No.

Tool

Ord r No.

Tool

D scription

Pow r

H ad

Ord r No.

Adapt r

D scription

Figur

No.

63811-4 0

6381

1050

Hand Crimp Frame (Short)

N/A

6381

100

Hand Crimp Frame (Long)

N/A

63816

0200

Battery Power

Tool (110 V)

63816

0300

Power Crimp Head

63816

0250

Battery Power

Tool (220 V)

63816

0300

Power Crimp Head

Applications for th Tool Kit

Hand Crimp Tool

Batt ry Pow r d Tool

Figur

WARNING: NEVER operate service, install tool kits or adjust the Power Crimp Head without proper

instruction and without first reading and understanding the instructions in the proper manual or specification

sheet. See chart above for the correct manual or specification sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the

power is turned off.

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.

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING

KIT

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05 UNCONTROLLED COPY Page of 8

Revision: B Revision Date: 0 -24-1

RATCHET

RELEASE SCREW

Figur

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

It m Numb r

Ord r Numb r

D scription

Quantity

63810

1000

Hand

Crimp Frame (Long)

63811

Tool Kit with

Locator

63811

Locator Base

63811

4 5

Locator

REF

Tool Kit for MLX Crimp Terminals

Doc No: ATS-638114 HM Release Date: 04-29-05 UNCONTROLLED COPY Page 8 of 8

Revision: B Revision Date: 0 -24-1

Figur

Long

BHCS

Long

BHCS

Long

BHCS

POWER HEAD PARTS LIST

It m

Ord r No

Engin ring No.

D scription

Quantity

63816-0300 63816-0300 Power Crimp Head 1

63811-4 0 63811-4 0 Tool Kit 1

Application Tooling Support

Phon : (402) 458-TOOL (8665)

E-Mail: [email protected]

W bsit : www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed

herein belong to their respective owners.

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