Molex 63828-0600 Manuel utilisateur

Hand Crimp Tool for EconoLatch Male and Female Crimp Terminals

Doc No: ATS-6382806HM Release Date: 07-25-16 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 07-25-16

CONDUCTOR BRUSH

STRIP LENGTH

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

SEAM

INSULATION

CRIMP

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63828-0670

Hand Crimp Tool

Order No. 63828-0600

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 2 compliant as indicated 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)

Products: EconoLatch Male and Female Terminals, 16 AWG-18AWG UL1061 and 18 AWG UL1007 wires.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

IPC/WHMA-A620 (1)

Terminal (2)

AWG

In.

150180

150180-1016

16-18

1.70-2.10

.067-.083

1.70-2.05

.067-.081

3.18-3.96

.125-.156

150181

150181-1016

16-18

1.70-2.10

.067-.083

1.70-2.05

.067-.081

3.18-3.96

.125-.156

(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range (example 16AWG UL1061 and 18AWG UL1007).

(2) Overall insulation OD specification for terminal.

DEFINITION OF TERMS

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

TYPE 4A

Hand Crimp Tool for EconoLatch Male and Female Crimp Terminals

Doc No: ATS-6382806HM Release Date: 07-25-16 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 07-25-16

CRIMP SPECIFICATIONS

Terminal Series No.

Bell mouth

Cut-off Tab Maximum

Conductor Brush

(Contact side)

In.

150180

0.10-0.60

.004-.024

0.40

.016

0.25-0.65

.010-.030

150181

0.10-0.60

.004-.024

0.40

.016

0.25-0.65

.010-.030

To achieve the conductor brush specification, special care must be taken, or a light touch

must be maintained while presenting wire against the wire stop.

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 (Max)

150180

150181

After crimping, the conductor profile should measure the following.

Terminal

Series No

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Profile

Height

Width

Height (Max.)

Width (Max.)

AWG

mm2

In.

Lb.

150180

---

1.15-1.25

.045-.049

1.90-2.00

.075-.079

2.30

.090

2.45

.096

133.5

30.0

---

1.00-1.10

.039-.043

1.90-2.00

.075-.079

2.30

.090

2.25

.089

89.0

20.0

2.40

.094

2.45

.096

89.0

20.0

150181

---

1.15-1.25

.045-.049

1.90-2.00

.075-.079

2.30

.090

2.45

.096

133.5

30.0

---

1.00-1.10

.039-.043

1.90-2.00

.075-.079

2.30

.090

2.25

.089

89.0

20.0

2.40

.094

2.45

.096

89.0

20.0

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.

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

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

3. Press down on the wire stop on the locator. Insert the terminal into the nest opening as shown in Figure 1.

4. Return the locator to its original position.

SWING LOCATOR

OPEN

TERMINAL

Hand Crimp Tool for EconoLatch Male and Female Crimp Terminals

Doc No: ATS-6382806HM Release Date: 07-25-16 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 07-25-16

PIVOT

LOCATOR

Figure 4

REMOVE

CRIMPED WIRE

OPEN WIRE

STOP

5. While holding the locator against the hand tool insert the proper wire size into the terminal. See Figure 2.

6. Push the wire until it stops. See Figure 3.

Note: Do not push the wire too far. This will result in the

locator being rotated out of position and the crimp will be

damaged.

7. Close the tool until the ratchet releases, the tool handles will

then spring open.

8. Before removing the crimped wire, pivot the terminal locator

out. See Figure 4.

9. While holding the locator out lift up on the wire stop at the

same time, carefully remove the crimped terminal.

Note: The tamper proof ratchet action will not release the tool

until it has been fully closed.

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 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 8.

WIRE

CONDUCTOR

PUNCH

WIRE STOP

BLADE

Figure 2

LOCATOR

CONDUCTOR

ANVIL

TERMINAL

WIRE

CONDUCTOR

PUNCH

WIRE AGAINST

WIRE STOP

Figure 3

INSULATION

PUNCH

INSULATION

ANVIL

Hand Crimp Tool for EconoLatch Male and Female Crimp Terminals

Doc No: ATS-6382806HM Release Date: 07-25-16 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 07-25-16

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.

Applications for the Modular Crimp Head

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.

Hand Crimp Tool for EconoLatch Male and Female Crimp Terminals

Doc No: ATS-6382806HM Release Date: 07-25-16 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 07-25-16

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR POWER

CRIMP

ADAPTER

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

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63828-0670

63816-0000

Hand Crimp Frame (Short)

N/A

63816-0050

Hand Crimp Frame (Long)

N/A

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

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure 5

Figure 6

Figure 7

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for EconoLatch Male and Female Crimp Terminals

Doc No: ATS-6382806HM Release Date: 07-25-16 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 07-25-16

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 8

M4 X 8mm

LONG BHCS

PARTS LIST

Item

Order Number

Description

Quantity

63828-0670

Modular Crimp Head

63816-0500

Hand Crimp Frame (Long)

63828-0675

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Application Tooling Support

2200 Wellington Court

Lisle, IL 60532 USA

Phone: +1-402-458-TOOL (8665)

E-mail: [email protected]

Visit our Website at www.molex.com/applicationtooling

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