Molex 63811-7100 Bedienungsanleitung

Hand Tool for .093" Pin and Socket Crimp Terminals and Claspcon™ Crimp Terminal Socket

Doc No: ATS-638117100 Release Date: 02-12-07 UNCONTROLLED COPY Page 1 of 6

Revision: B Revision Date: 03-28-08

INSULATI

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

TYPE 2C

HAND CRIMP TOOL

SPECIFICATION SHEET

Order No. 63811-7100

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 IPC/WHMA-A-620 Class 2 and RoHS compliant

SCOPE

Products: .093” Pin and Socket 14-18 AWG and 24-30 AWG and Claspcon™ Crimp Terminal Socket 24-30 AWG

Terminal Order No. Wire Size



Insulation Diameter

Strip LengthTerminal

Series No.

Loose Piece



Reel AWG

mm² mm In. mm In.

02-09-1141

39-00-0318

02-09-1142

39-00-0317

02-09-1144

39-00-0320

02-09-5146

39-00-0319

02-09-5147

39-00-0322

39-00-0315

39-00-0321

1433

39-00-0316

24-30

0.20-0.05

0.76-1.52 .030-.060 3.96-5.53

.156-.218

02-09-2143

39-00-0324

02-09-2141

39-00-0325

02-09-6145

39-00-0326

02-09-2149

39-00-0323

1434

02-09-6144

24-30

0.20-0.05

0.76-1.52 .030-.060 3.96-5.53

.156-.218

1881-3 02-08-1104

02-08-1103

24-30

0.20-0.05

0.76-1.52 .030-.060 3.96-5.53

.156-.218

42477 02-09-1615

14-18

2.00-0.80

2.36-3.55 .093-.140 3.96-5.53

.156-.218

42478 02-09-2612

02-09-2611

14-18

2.00-0.80

2.36-3.55 .093-.140 3.96-5.53

.156-.218



Follow the Cut-Off Tab specifications on Applicator specification sheets. These Terminals in the 1433, 1434, and 1881 series

cannot be removed from the reel by manual cutting. An applicator must be used or the terminals will not function properly.



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 Tool for .093" Pin and Socket Crimp Terminals and Claspcon™ Crimp Terminal Socket

Doc No: ATS-638117100 Release Date: 02-12-07 UNCONTROLLED COPY Page 2 of 6

Revision: B Revision Date: 03-28-08

CONDITIONS:

After crimping, the conductor profiles should measure the following (see Note).

Conductor Crimp Insulation Crimp

Wire Size Height (Ref) Width (Ref)

Height (Ref)

Maximum Width (Ref)

Pull Force

Minimum



Profile

Terminal Series No.

AWG

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

24 0.20 0.86-0.94

.034-.037

1.60 .063 1.35 .053 1.90 .075 33.5 10.00

26 0.12 0.86-0.94

.034-.037

1.60 .063 1.32 .051 1.90 .075 20.1 6.00

28 0.08 0.86-0.94

.034-.037

1.60 .063 1.28 .050 1.90 .075 13.3 3.00

1433

30 0.05 0.84-0.91

.033-.036

1.60 .063 1.28 .050 1.90 .075 6.7 1.50

24 0.20 0.86-0.94

.034-.037

1.60 .063 1.35 .053 1.90 .075 33.5 10.00

26 0.12 0.86-0.94

.034-.037

1.60 .063 1.32 .051 1.90 .075 20.1 6.00

28 0.08 0.86-0.94

.034-.037

1.60 .063 1.28 .050 1.90 .075 13.3 3.00

1434

30 0.05 0.84-0.91

.033-.036

1.60 .063 1.28 .050 1.90 .075 6.7 1.50

24 0.20 0.86-0.94

.034-.037

1.60 .063 1.35 .053 1.90 .075 33.5 10.00

26 0.12 0.86-0.94

.034-.037

1.60 .063 1.32 .051 1.90 .075 20.1 6.00

28 0.08 0.86-0.94

.034-.037

1.60 .063 1.28 .050 1.90 .075 13.3 3.00

1881-3

30 0.05 0.84-0.91

.033-.036

1.60 .063 1.28 .050 1.90 .075 6.7 1.50

14 2.00 1.85-1.96

.073-.077

2.49 .098 3.28 .129 4.85 .191 222.6

50.00

16 1.30 1.40-1.50

.055-.059

2.75 .108 3.80 .150 3.70 .146 133.5

30.00

42477

18 0.80 1.30-1.40

.051-.055

2.75 .108 3.75 .148 3.70 .146 89.0 20.00

14 2.00 1.85-1.96

.073-.077

2.49 .098 3.28 .129 4.60 .181 222.6

50.00

16 1.30 1.40-1.50

.055-.059

2.75 .108 3.80 .150 3.70 .146 133.5

30.00

42478

18 0.80 1.30-1.40

.051-.055

2.75 .108 3.75 .148 3.70 .146 89.0 20.00



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

1. Profile A: 0.76-1.52mm (.030-.060 inch)

2. Profile B: 2.79-3.55mm (.110-.140 inch)

3. Profile C: 2.36-3.14mm (.093-.124 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.

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 Tool for .093" Pin and Socket Crimp Terminals and Claspcon™ Crimp Terminal Socket

Doc No: ATS-638117100 Release Date: 02-12-07 UNCONTROLLED COPY Page 3 of 6

Revision: B Revision Date: 03-28-08

3. When using the locator, press down on the wire stop on the locator as shown in Figure 2. Insert the proper

terminal into the proper nest opening. Make sure when choosing the nest opening, it will correspond with the

A, B, or C profile on the hand tool.

4. Return the locator to its original position. 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 3.

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.

6. 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.

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 under Conditions.

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 new locator by putting over the brass pivot shaft and snapping it into place.

SWING

LOCATOR

OPEN

PRESS D

OWN

ON BRASS

PIVOT SHAFT

LIFT UP LOCATOR

JAWS

OPEN

Figure 4

TERMINAL

PUSH HERE

TO OPEN

WIRE STOP

SWING OPEN

LOCATOR

TERMINAL

IN PLACE

Figure 2

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE AGAINST

STOP

Figure 3

WIRE STOP

WIRE

Hand Tool for .093" Pin and Socket Crimp Terminals and Claspcon™ Crimp Terminal Socket

Doc No: ATS-638117100 Release Date: 02-12-07 UNCONTROLLED COPY Page 4 of 6

Revision: B Revision Date: 03-28-08

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. Use light oil, such as 30 weight automotive oil, at

the oil points. Every 5,000 crimps, or 3 months, to significantly enhance the tool life. See Figure 6.

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 6.

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.

RATCHET

RELEASE LEVER

Figure 6

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELOAD

CHECK POINT

25.4MM

SETTING WHEEL

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 5

Hand Tool for .093" Pin and Socket Crimp Terminals and Claspcon™ Crimp Terminal Socket

Doc No: ATS-638117100 Release Date: 02-12-07 UNCONTROLLED COPY Page 5 of 6

Revision: B Revision Date: 03-28-08

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 Tool for .093" Pin and Socket Crimp Terminals and Claspcon™ Crimp Terminal Socket

Doc No: ATS-638117100 Release Date: 02-12-07 UNCONTROLLED COPY Page 6 of 6

Revision: B Revision Date: 03-28-08

RATCHET

RELEASE LEVER

Figure 7

M4 X 5LG

BHCS

PARTS LIST

Item Number Order Number Description Quantity

REF 63811-7100 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 63811-7175 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

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