Molex 63811-6400 Bedienungsanleitung

Hand Crimp Tool for SPOX™ Terminals

Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 1 of 6

Revision: B Revision Date: 03-29-08

TYPE 2C

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

HAND CRIMP TOOL

SPECIFICATION SHEET

Order No. 63811-6400

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



This tool is WHMA-IPCA620 Class 2 and RoHS compliant

SCOPE

Products: Pico-SPOX™ Crimp Female Terminal, 24-30 AWG.

Terminal Order No. Wire Size Wire Type



Insulation Diameter

Maximum Strip Length

Terminal

Series No. Loose Piece



Reel AWG mm² AWG Type mm In. mm In.

24 0.20 24 UL1061 1.15 .045 1.05-1.54 .041-.061

26 UL1061

28 UL1061

87421 87421-0000 26-30 0.12-0.05

30 UL1571

1.00 .039 1.05-1.54 .041-.061



Customer to cut off terminal from reel: 0.29mm (.011”) maximum Cut-off Tab.



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.

Hand Crimp Tool for SPOX™ Terminals

Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 2 of 6

Revision: B Revision Date: 03-29-08

TERMINAL

SWING OPEN

PRESS HERE ON LOCATOR

LOCATOR

TERMINAL IN PLACE

Figure 2

FRAME

CONDITIONS:

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

Conductor Crimp Insulation Crimp

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

Height (Ref.)

Width (Ref.)

Pull Force

Minimum



Profile

Terminal Series No

AWG

2mm In. mm In. mm In. mm In. N Lb. A B

87421 24 0.20 0.56-0.60

.022-.024

1.00 .039 1.40 .055 1.10 .043 29.4

6.60

87421 26 0.12 0.52-0.58

.020-.023

1.00 .039 1.24 .049 1.10 .043 19.6

4.40

87421 28 0.08 0.52-0.58

.020-.023

1.00 .039 1.24 .049 1.10 .043 9.8 2.20

87421 30 0.05 0.52-0.58

.020-.023

1.00 .039 1.24 .049 1.10 .043 6.7 1.50



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

Profile A: 1.00-1.15mm (.039-.045 inch)

Profile B: 0.65-1.00mm (.025-.039 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.

Crimping Terminals

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

2. Swing the terminal locator away from the crimp tool shown in

Figure 2. Gently press on the locator to open the wire stop.

Some terminals with large insulation grips may interfere with the

crimp tooling when swinging the locator into position. The

terminal must then be loaded into the locator in the closed/crimp

position.

Figure 1

LOCATOR

JAWS OPEN

Hand Crimp Tool for SPOX™ Terminals

Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 3 of 6

Revision: B Revision Date: 03-29-08

SWING

LOCATOR

OPEN

PRESS DOWN ON

BRASS PIVOT SHAFT

LIFT UP

LOCATOR

JAWS

OPEN

Figure 4

3. When using the locator, swing the locator away from the crimp

tool, and gently press the locator against the tool frame as

shown in Figure 2. The wire stop will automatically open.

Insert the proper terminal into the proper nest opening. Make

sure when choosing the nest opening, it will correspond with

the A or B profile on the hand tool.

4. Return the locator to its original position.

5. Insert the proper wire over the terminal. Some large O.D. wires

may need to be placed into the terminal before closing the tool.

Gently touch the wire stop with the end of the wire. See Figure

6. Compress the terminal by squeezing the tool handles until the

ratchet mechanism cycle has been completed. Release

handles to open the jaws.

7. 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.

8. 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.

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 on page 2.

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. 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 the

top of the brass pivot shaft. See Figure 4.

4. Replace it with the proper locator by putting over the brass pivot shaft and snapping it into place.

WIRE

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE STOP

WIRE

AGAINST STOP

Figure 3

Hand Crimp Tool for SPOX™ Terminals

Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 4 of 6

Revision: B Revision Date: 03-29-08

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

fine piece of 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, shown in Figure 6will

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 the ratchet release lever. See Figure

How to Adjust Tool Preload

(See Figure 6)

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. Remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel.

2. Remove the locking screw with a 2mm hex wrench. The wrench set (63810-0101), is not supplied. It is sold

separately from the hand tool.

3. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase

handle force.

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

5. Replace the handle grip.

6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 5

RATCHET

RELEASE LEVER

Figure 6

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELO

CHECK POINT

25.4MM

SETTING WHEEL

Hand Crimp Tool for SPOX™ Terminals

Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 5 of 6

Revision: B Revision Date: 03-29-08

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 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

12.7mm (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 SPOX™ Terminals

Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 6 of 6

Revision: B Revision Date: 03-29-08

PARTS LIST

Item Number Order Number Description Quantity

REF 63811-6400 Hand Crimp Tool Figure 7

1 63810-0101 Wrench Set (Not included) 0

2 63810-0102 Locator Base Assembly 1

3 63810-0103 Repair Kit (Not included) 0

4 63811-6475 Locator 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

RATCHET

RELEASE LEVER

Figure 7

M4 X 5LG

BHCS

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