Molex 63811-5600 User manual

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 1 of 8

Revision: F Revision Date: 05-24-11

Application Tooling

Specification Sheet

Tool Kit

Order No. 6 811-5670

Hand Crimp Tool

Order No. 6 811-5600

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

 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.

 Many different Tool kits can be used with a single Battery Powered Tool.

 This tool is IPC/WHMA-A-620 Class 2 and RoH compliant.

SCOPE

Products: 4.64mm (.183") Crimp Terminal, Pin, 14-18 AWG.

Terminal Series No. Terminal Order No. Wire Size Insulation Diameter Strip Length

Available in Reel form only AWG mm² mm in mm in

84524 84524-0008 84524-0016

14 2.09 3.05-3.81 .120-.150

16 1.33 2.41-3.05 .095-.120 4.45 .175

18 0.82 1.91-2.41 .075-.095

84525 84525-0017 84525-0039

14 2.09 3.05-3.81 .120-.150

16 1.33 2.41-3.05 .095-.120 4.45 .175

18 0.82 1.91-2.41 .075-.095

84590

84590-0022

84590-0023

84590-0028

84590-0029

84590-0037

84590-0038

14 2.09 3.05-3.81 .120-.150

4.45 .175 16 1.33 2.41-3.05 .095-.120

18 0.82 1.91-2.41 .075-.095

Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab.

 IPC/WHMA-A-620 Class 2 only 3.05-3.40mm (.120-.134”)

TYPE 4C

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 2 of 8

Revision: F Revision Date: 05-24-11

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

BEND UP

TWISTING

ROLLING

BEND

DOWN

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

WIRE

DEFINITION OF TERMS

CRIMP SPECIFICATION

Terminal Series No. Bell Mouth Bend up Bend down Twist Roll Conductor Brush

mm In. Degree Degree mm In.

84524 84525 84590 0.13-0.37 .005-.015 5 5 5 10 0.75-1.25 .030-.050

Seam

eam shall not be open and no wire allowed out of the crimping area

CONDITIONS:

After crimping, the conductor profiles should measure the following ( ee notes below).

Terminal Series No. Wire Size Conductor Pull Force

Minimum Profile

Crimp Height (Ref) Crimp Width (Ref)

AWG

mm2 mm in. mm in. N Lb. 14 16 18

84524

14 2.09 1.73-1.81 .068-.071 2.55 .100 111.2 25.0 X

16 1.33 1.48-1.56 .058-.061 2.55 .100 111.2 25.0 X

18 0.82 1.36-1.44 .054-.057 2.55 .100 111.2 25.0 X

84525

14 2.09 1.73-1.81 .068-.071 2.55 .100 111.2 25.0 X

16 1.33 1.48-1.56 .058-.061 2.55 .100 111.2 25.0 X

18 0.82 1.36-1.44 .054-.057 2.55 .100 111.2 25.0 X

84590

14 2.09 1.73-1.81 .068-.071 2.55 .100 111.2 25.0 X

16 1.33 1.48-1.56 .058-.061 2.55 .100 111.2 25.0 X

18 0.82 1.36-1.44 .054-.057 2.55 .100 111.2 25.0 X

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.

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.

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 3 of 8

Revision: F Revision Date: 05-24-11

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool or die.

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the steps below:

Anvils and Punches Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHC and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHC and tighten in place. ee

Figure 1.

Locator Installation and Removal

Follow the steps below to install or replace the locator. ee Figure 2.

To install the locator

1. Position the locator with

the hole over the brass

pivot shaft and snap it into

place.

To remove the locator

1. Open the crimp hand tool.

2. wing 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. lip the locator off the top of the brass pivot

shaft.

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

LOCATOR TERMINAL IN PLACE

Figure

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 4 of 8

Revision: F Revision Date: 05-24-11

HANDLE

OPEN

LOCATOR

CLOSED

Figure 5

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

Figure 6

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

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. elect the desired terminal listed in the preceding

charts.

2. wing the terminal locator away from the crimp tool

shown in Figure 3. ome 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. ee Figure 4.

3. Press down on the wire stop on the locator as shown in Figure 5. Insert the proper terminal into the proper

nest opening. Make sure when choosing the nest opening, it will correspond with the 14, 16, or 18 profile on

the hand tool. ee Figure 4.

4. Return the locator to its original position.

5. Insert the proper wire over the terminal. Gently touch the wire stop with the end of the wire.

ee Figure 5 and 6.

6. 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.

7. 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.

8. Visually inspect the crimped terminal for proper crimp location.

For the Battery Power Tool:

1. Cycle the Battery Power Tool to crimp the terminal to the wire.

2. 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.

3. Visually inspect the crimped terminal for proper crimp location.

Figure 4

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

LOCATOR

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 5 of 8

Revision: F Revision Date: 05-24-11

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 in the tool head are

protected with a thin coat of high quality

machine oil. Do not oil excessively. This

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. The use of light oil, such as 30 weight automotive oil, every

5,000 crimps or monthly, will significantly enhance the tool life and ensure a stable calibration. ee Figure 7A

or 7B for lubrication points.

4. tore the tool in a clean and dry area when not in use.

Miscrimps or Jams for Crimp Hand Tools Only

(See Figure 10

hould 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 rotating the small slotted screw marked with an arrow. ee Figure 10.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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. hould such a defect occur, we will repair or exchange the tool kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

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.

CAUTION: Repetitive use of this tool should be avoided.

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.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Figure 7B

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 6 of 8

Revision: F Revision Date: 05-24-11

% 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. ee the Molex web site for the Quality Crimp Handbook for more information on pull

testing.

% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power Head

Order No.

Adapter

Description

Figure

No.

63811-5670

63810-1050

Hand Crimp Frame ( hort) N/A N/A 8

63810-1000

Hand Crimp Frame (Long) N/A N/A 8

63816-0200

Battery Power Tool (110 V)

63816-0300 Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300 Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool Battery Powered Tool

Figure 8 Figure 9

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper

instruction and without first reading and understanding the instructions in the proper Manual or

pecification heet. ee Chart above for the correct Manual or pecification heet.

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

power is turned off.

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.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 7 of 8

Revision: F Revision Date: 05-24-11

RATCHET

RELEASE SCREW

Figure 10

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number Order Number Description Quantity

1 63810-1000 Hand Crimp Frame (Long) 1

2 63811-5670 Tool Kit with Locator 1

3 63811-5573 Locator Base 1

4 63811-5675 Locator (only) REF

Tool Kit for 4.64mm (.183") Crimp Terminal, Pin

Doc No: AT -6381156HM Release Date: 01-18-07 UNCONTROLLED COPY Page 8 of 8

Revision: F Revision Date: 05-24-11

Figure 11

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item Order No Engineering No. Description Quantity

63816-0300 63816-0300 Power Crimp Head 1

63811-5670 63811-5670 Tool Kit 1

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