Molex 63811-9370 Manuel utilisateur

Hand Crimp Tool for MOX 0.635mm (.025") Receptacle Crimp Terminals

oc No: ATS-6381193HM Release ate: 08-24-07 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision ate: 08-03-10

Application Tooling

Specification Sheet

Modular Crimp ead

Order No. 63811-9370

and Crimp Tool

Order No. 63811-9300

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

% A-620 Class 3 compliant and RoHS compliant

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).

% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).

SCOPE

Products: MOX 0.635mm (.025") Receptacle Crimp Terminal, 0.22-0.75mm² and 20-22 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size

Actual mm²

Wire Type

Insulation Diameter Strip Length

mm In. mm In.

98658

98658-1211

98658-1221

98658-1231

0.22mm² 0.22 I 1.10-1.25

.043-.049

2.60-3.30

.102-.130

0.35mm² 0.34 IR 1.25-1.40

.049-.055

2.60-3.30

.102-.130

22 AWG 0.35 TXL 1.40-1.60

.055-.063

2.60-3.30

.102-.130

0.50mm² 0.495 I 1.40-1.50

.055-.059

2.60-3.30

.102-.130

0.50mm² 0.495 IR 1.40-1.60

.055-.063

2.60-3.30

.102-.130

20 AWG 0.562 TXL 1.75-1.90

.069-.075

2.60-3.30

.102-.130

0.60mm² 0.59 IR 1.75-1.90

.069-.075

2.60-3.30

.102-.130

98658-1212

98658-1222

98658-1232

0.75 mm² 0.79 I 1.60-1.80

.063-.071

3.35-3.65

.132-.144

98658-1213

98658-1223

98658-1233

0.22mm² 0.22 I 1.15-1.25

.045-.049

2.60-3.30

.102-.130

0.35mm² 0.34 IR 1.25-1.40

.049-.055

2.60-3.30

.102-.130

22 AWG 0.35 TXL 1.40-1.60

.055-.063

2.60-3.30

.102-.130

0.50mm² 0.495 I 1.40-1.50

.055-.059

2.60-3.30

.102-.130

0.50mm² 0.495 IR 1.40-1.60

.043-.049

2.60-3.30

.102-.130

TYPE 4A

Hand Crimp Tool for MOX 0.635mm (.025") Receptacle Crimp Terminals

oc No: ATS-6381193HM Release ate: 08-24-07 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision ate: 08-03-10

INSULATION

CRIMP

BRUS

STRIP

LENGT

CRIMP EIG T

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP TWISTING

SEAM

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the

scope.

CRIMP SPECIFICATION

After crimping, the conductor profile should measure the following.

Terminal

Series No.

Wire Size

Actual mm²

Wire Type

Conductor Profile AWG

Crimp eight (Ref) Crimp Width (Ref)

0.22-0.35mm2

22 AWG

0.6-0.75mm2

20 AWG 0.5mm2

mm In. mm In.

98658

22 AWG 0.35 TXL 0.68-0.78

.027-.031-

1.40 .055 X

0.22mm² 0.22 I 0.68-0.78

.027-.031-

1.40 .055 X

0.35mm² 0.34 IR 0.68-0.78

.027-.031-

1.40 .055 X

20 AWG 0.50 TXL 0.90-1.00

.039-.043 1.40 .055 X

0.60mm² 0.59 IR 1.00-1.10

.039-.043 1.40 .055 X

0.75mm 0.79 I 1.00-1.10

.039-.043 1.40 .055 X

0.50mm² 0.50 I 0.83-0.93

.033-.037 1.40 .055 X

0.50mm² 0.50 IR 0.83-0.93

.033-.037 1.40 .055 X

Terminal Series No.

Wire Size

Actual mm²

Wire Type

Insulation Pull Force Minimum

Crimp eight (Ref)

Crimp Width (Ref)

mm In. mm In. N Lb.

98658

22 AWG 0.35 TXL 1.75 .069 1.90 .075 60.0 13.50

0.22mm² 0.22 I 1.75 .069 1.90 .075 50.0 11.24

0.35mm² 0.34 IR 1.75 .069 1.90 .075 60.0 13.50

20 AWG 0.50 TXL 1.80 .071 2.00 .079 80.0 17.99

0.60mm² 0.59 IR 2.15 .085 2.15 .085 80.0 17.99

0.75mm 0.79 I 2.15 .085 2.15 .085 100.0 22.50

0.50mm² 0.50 I 1.70 .067 1.90 .075 80.0 17.99

0.50mm² 0.50 IR 1.70 .067 1.90 .075 80.0 17.99

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.

Hand Crimp Tool for MOX 0.635mm (.025") Receptacle Crimp Terminals

oc No: ATS-6381193HM Release ate: 08-24-07 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision ate: 08-03-10

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. With the hand tool in the open position, pivot the terminal

locator open. See Figure 1.

2. Insert the terminal fully into the correct profile until the

terminal is fully seated and stops.

3. Gently pivot the locator closed.

4. Slide the pre-stripped wire into the insulation stop. See Figure 2. The wire strands pass thru the

insulation stop slot, while the end of the insulation touches the stop. Be sure to hold the wire in place until

the terminal is fully crimped. See Figure 3.

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 good brush control and a consistent bell mouth the crimping instructions must be followed.

TERMINAL

SEATED IN

LOCATOR

OPEN

Figure 1

AND TOOL

OPEN

Figure 3

WIRE

TERMINAL

LOCATOR

INSULATION

PUNC

INSULATION

ANVIL

INSULATION

STOP

CONDUCTOR

ANVIL

CONDUCTOR

PUNC

INSULATION

OF T E WIRE

STOPS ERE

INSULATION

PUNC

TERMINAL

LOCATOR

INSULATION

STOP

Figure 2

CONDUCTOR

PUNC

Hand Crimp Tool for MOX 0.635mm (.025") Receptacle Crimp Terminals

oc No: ATS-6381193HM Release ate: 08-24-07 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision ate: 08-03-10

INCORRECT

Figure 5

CORRECT INCORRECT

Terminal Locator Replacement/Change Over

This section describes the procedure for changing locators.

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Place the proper locator, (See Chart on page 2), on the hand tool.

Install the M4 BHCS. See Figure 4.

2. Tighten the screw enough to hold the locator. Make sure the

locator can still float freely with hand pressure.

3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then

gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place and slowly tighten the M4 BHCS.

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. o 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. o 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 30 weight

automotive oil) used at the oil 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. 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 9.

M4 B CS

PIVOT LOCATOR

Figure 4

Hand Crimp Tool for MOX 0.635mm (.025") Receptacle Crimp Terminals

oc No: ATS-6381193HM Release ate: 08-24-07 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision ate: 08-03-10

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: 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.

3. 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.

3. 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.

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 63800-0029 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.

Hand Crimp Tool for MOX 0.635mm (.025") Receptacle Crimp Terminals

oc No: ATS-6381193HM Release ate: 08-24-07 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision ate: 08-03-10

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

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. isconnect 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.

63811-9370

63816-0000

Hand Crimp Frame (Short) N/A N/A 6

63816-0050

Hand Crimp Frame (Long) N/A N/A 6

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adapter 8

Applications for the Modular Crimp ead

and Crimp Tool Battery Powered Tool Air Powered Tool

Figure 6 Figure 7 Figure 8

MODULAR

CRIMP

EAD

LOCKING

PINS

AND CRIMP

FRAME LONG

OR S ORT

Hand Crimp Tool for MOX 0.635mm (.025") Receptacle Crimp Terminals

oc No: ATS-6381193HM Release ate: 08-24-07 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision ate: 08-03-10

RATC ET

RELEASE LEVER

ANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 9

M4 X 6mm

LONG B CS

PARTS LIST

and Crimp Tool 63811-9300

Item

Order Number

Description Quantity

1 63811-9370 Modular Crimp Head 1

2 63816-0000 Hand Crimp Frame (Short)

3 63811-9375 Locator-Blue 1

4 63816-0001 Locking Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

http://www.molex.com

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