Molex 63811-6170 Manuel utilisateur

Hand Crimp Tool for MX150 Blade Female Crimp Terminals

Doc No: ATS-6 81161HM Release Date: 0 -21-06 UNCONTROLLED COPY Page 1 of 6

Revision: G Revision Date: 07-29-10

Application Tooling

Specification Sheet

Modular Crimp ead

Order No.

63811

and Crimp Tool

Order No.

3811

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

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.6 816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 6 816-0700).

% Can also be used in the Battery Powered Tool Order No.6 816-0200 (110 V) or 6 816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 6 816-0600).

SCOPE

Products: MX150 1.50mm (.591") Pitch, MX150 Receptacle Female Crimp Terminals, 1.00 and 1.50 Metric

wires.

Terminal

Series No.

Terminal Order No. Wire Size Insulation Diameter Strip Length

●Reel AWG mm²

mm In. mm In.

001

001-2004

001-2022

001- 004

001- 022

Metric Only

1.00

1.90-2.10

.075-.08

4.70-5.60

.185-.220

001-4002

001-4022

001-5002

001-5022

001-200

001-2021

001- 00

001- 021

Metric Only

1.50

2.20-2.40

.087-.094

4.70-5.60

.185-.220

001-4001

001-4021

001-5001

001-5021

012 012-2002

012-2022

012- 002

012- 022

Metric Only

1.00

1.90-2.10

.075-.08

4.70-5.60

.185-.220

012-2001

012-2021

012- 001

012- 021

Metric Only

1.50

2.20-2.40

.087-.094

4.70-5.60

.185-.220

4750 4750-0002

4750-1002

Metric Only

1.00

1.90-2.10

.075-.08

4.70-5.60

.185-.220

4750-0001

4750-1001

Metric Only

1.50

2.20-2.40

.087-.094

4.70-5.60

.185-.220

●Customer to cut off terminal from reel: 0.25mm (.010”) maximum Cut-off Tab.

Terminals were validated per USCAR-21 using the following wire specifications:

M1L-12 A (TXL), M1L-1 5A1 (UTX), and M1L-126A1 (metric-TXL).

Customers are required to complete validation testing if tooling purchased outside Molex Inc.

and/or wire specifications are different than above.

TYPE 4A

Hand Crimp Tool for MX150 Blade Female Crimp Terminals

Doc No: ATS-6 81161HM Release Date: 0 -21-06 UNCONTROLLED COPY Page 2 of 6

Revision: G Revision Date: 07-29-10

INSULATION

CRIMP

BRUS

STRIP LENGT

BELL MOUT

CRIMP

EIG T

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF

TAB

SEAM

TERMINAL WIDT

NOT TO EXCEED

2.65mm AFTER CRIMP

WIRE BEND

0.30

T IS AREA

WIRE BRUS MUST BE

FLUS OR BELOW TOP

OF CONDUCTOR CRIMP

DEFINITION OF TERMS

CRIMP SPECIFICATION

Terminal Series No. Bell mouth 



 Conductor Brush

mm In. mm In.

001 0.25-1.25 .010-.049 0.15-0.40 .006-.016

012 0.25-1.25 .010-.049 0.15-0.40 .006-.016

4750 0.25-1.25 .010-.049 0.15-0.40 .006-.016





Wire brush to be below top of conductor crimp.

Terminal Series No. Bend up Bend down Twist Roll Seam

Seam shall not be

open and no wire allowed

out of the crimping area

Degree Degree

001 



Crimped terminals and up to 5mm of wire past the insulator

cutoff tab must freely fit in the Checking Aid, Part No. 6 868-2008

012

4750





Order Separately

After crimping, the crimp profiles should measure the following:

Terminal Series No. Wire Size Conductor Profile

AWG

Crimp eight Crimp Width

AWG mm2 mm In. mm In. 1.00 1.50

001 Metric Only 1.00 1.25-1. 5 .049-.05 2.05-2.25 .081-.089 X

Metric Only 1.50 1. 5-1.45 .05 -.057 2. 5-2.55 .092-.100 X

012 Metric Only 1.00 1.25-1. 5 .049-.05 2.05-2.25 .081-.089 X

Metric Only 1.50 1. 5-1.45 .05 -.057 2. 5-2.55 .092-.100 X

4750 Metric Only 1.00 1.25-1. 5 .049-.05 2.05-2.25 .081-.089 X

Metric Only 1.50 1. 5-1.45 .05 -.057 2. 5-2.55 .092-.100 X

Hand Crimp Tool for MX150 Blade Female Crimp Terminals

Doc No: ATS-6 81161HM Release Date: 0 -21-06 UNCONTROLLED COPY Page of 6

Revision: G Revision Date: 07-29-10

Terminal Series No. Wire Size Insulation Pull Force

Minimum

Crimp eight Crimp Width

AWG mm2 mm In. mm In. N Lb.

001 Metric Only 1.00 1.90-2.10 .075-.08 2.20-2.40 .086-.094 120.1 27.0

Metric Only 1.50 2.50-2.70 .098-.106 2.50-2.70 .098-.106 151.2 4.0

012 Metric Only 1.00 1.90-2.10 .075-.08 2.20-2.40 .086-.094 120.1 27.0

Metric Only 1.50 2.50-2.70 .098-.106 2.50-2.70 .098-.106 151.2 4.0

4750 Metric Only 1.00 1.90-2.10 .075-.08 2.20-2.40 .086-.094 120.1 27.0

Metric Only 1.50 2.50-2.70 .098-.106 2.50-2.70 .098-.106 151.2 4.0

ΤΤ

Τ Tool Qualification Notes:

1. Pull Force should be measured with no influence from the

insulation crimp.

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

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 Terminals

1. Lift the wire stop blade up.

2. Insert the terminal fully into the correct die profile and

the locator slot until the terminal is fully seated and

stops.

. Push down the wire stop blade. Make sure the wire

stop blade is fully seated on the terminal behind the

conductor grip section.

4. Slide the pre-stripped wire into the terminal; make sure

to aim the wire end towards the tip point on the wire

stop blade. See Figure 1. Align the wire so that it is

parallel to, and sitting into the terminal. Maintain a light

and constant pressure on the wire that is seated in the

terminal at all times. (Do not let go of the wire.) Be

sure to hold the wire and terminal in place until the

terminal is fully crimped. See Figure 2.

5. Close the tool until the ratchet releases.

6. Carefully remove the crimped terminal.

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

Note: To maintain a good brush control and a consistent bell mouth the crimping instructions must be

followed.

CONDUCTOR

PUNC

WIRE

LOCATOR

TERMINAL

INSULATION

PUNC

INSULATION

ANVIL

CONDUCTOR

ANVIL

WIRE STOP

BLADE

Figure 2

RETAINER

SPACER

TERMINAL

PRE-STRIPPED

WIRE

LOCATOR

Figure 1

WIRE STOP

BLADE

Hand Crimp Tool for MX150 Blade Female Crimp Terminals

Doc No: ATS-6 81161HM Release Date: 0 -21-06 UNCONTROLLED COPY Page 4 of 6

Revision: G Revision Date: 07-29-10

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.

. 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 0 weight

automotive oil) used at the oil points, every 5,000 crimps or 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 lifting the ratchet release lever. See Figure 6.

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 0

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: Repetitive use of this tool should be avoided.

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.

. Wear eye protection at all times.

4. Use only the Molex terminals specified for crimping with this tool.

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.

. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

Hand Crimp Tool for MX150 Blade Female Crimp Terminals

Doc No: ATS-6 81161HM Release Date: 0 -21-06 UNCONTROLLED COPY Page 5 of 6

Revision: G Revision Date: 07-29-10

MODULAR

CRIMP

EAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP EAD

LOCKING

PINS

LOCKING

PINS

AIR POWER

CRIMP

ADAPTER

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 6 800-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Applications for the Modular Crimp ead

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

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

power by unplugging or turn off the Actuator from its power source.

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.

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp ead

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

6 811-6170

6 816-0000

Hand Crimp Frame (Short) N/A N/A

6 816-0050

Hand Crimp Frame (Long) N/A N/A

6 816-0200

Battery Power Tool (110 V)

6 816-0600

Battery Power Crimp Adapter

6 816-0250

Battery Power Tool (220 V)

6 816-0600

Battery Power Crimp Adapter

6 816-0100

Air Power Tool 6 816-0700

Air Power Crimp Adapter 5

Applications for the Modular Crimp ead

and Crimp Tool Battery Powered Tool Air Powered Tool

Figure 3 Figure 4 Figure 5

MODULAR

CRIMP

EAD

LOCKING

PINS

AND CRIMP

FRAME LONG

OR S ORT

Hand Crimp Tool for MX150 Blade Female Crimp Terminals

Doc No: ATS-6 81161HM Release Date: 0 -21-06 UNCONTROLLED COPY Page 6 of 6

Revision: G Revision Date: 07-29-10

RATC ET

RELEASE LEVER

ANDLE

SPRING

CRIMPING

SPRING (2)

Figure

M4 X 12mm

LONG B CS

PARTS LIST

and Crimp Tool 63811-6100

Item

Order Number

Description Quantity

1 6 811-6170 Modular Crimp Head 1 (Ref)

2 6 816-0050 Hand Crimp Frame (Long)

1 (Ref)

6 811-6175 Locator 1

4 6 816-0001 Locking Pin 2

5 6 600-0525 Handle Spring 1

6 6 600-0520 Crimping Spring 2

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