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
mm
In.
mm
In.
mm
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)
mm
In.
mm
In.
mm
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)
Degree (Max)
150180
3
3
5
10
150181
3
3
5
10
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
mm
In.
Mm
In.
mm
In.
mm
In.
N
Lb.
16
18
18
150180
16
---
1.15-1.25
.045-.049
1.90-2.00
.075-.079
2.30
.090
2.45
.096
133.5
30.0
X
18
---
1.00-1.10
.039-.043
1.90-2.00
.075-.079
2.30
.090
2.25
.089
89.0
20.0
X
2.40
.094
2.45
.096
89.0
20.0
X
150181
16
---
1.15-1.25
.045-.049
1.90-2.00
.075-.079
2.30
.090
2.45
.096
133.5
30.0
X
18
---
1.00-1.10
.039-.043
1.90-2.00
.075-.079
2.30
.090
2.25
.089
89.0
20.0
X
2.40
.094
2.45
.096
89.0
20.0
X
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
N/A
5
63816-0050
Hand Crimp Frame (Long)
N/A
N/A
5
63816-0200
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
6
63816-0250
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
6
63816-0100
Air Power Tool
63816-0700
Air Power Crimp Adapter
7
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)
3
6
4
Figure 8
M4 X 8mm
LONG BHCS
2
5
1
PARTS LIST
Item
Order Number
Description
Quantity
1
63828-0670
Modular Crimp Head
1
2
63816-0500
Hand Crimp Frame (Long)
1
3
63828-0675
Locator
1
4
63816-0001
Locking Pin
2
5
63600-0525
Handle Spring
1
6
63600-0520
Crimping Spring
2
Application Tooling Support
2200 Wellington Court
Lisle, IL 60532 USA
Phone: +1-402-458-TOOL (8665)
Visit our Website at www.molex.com/applicationtooling
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