Molex 63811-6800 User manual

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 1 of 9

Revision: C Revision Date: 10-04-10

Application Tooling

Specification Sheet

Tool Kit

Order No. 6 811-6870

Hand Crimp Tool

Order No. 6 811-6800

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 6 816-0 00 Power Crimp Head which is installed

into the 6 816-0200 (110 V) or the 6 816-0250 (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 RoHS compliant.

SCOPE

Products: MLX™ Pin and Socket Crimp Terminal 14 - 20 AWG.

Terminal

Series No.

Terminal Order No. Wire Size 



Insulation

Diameter Maximum Strip Length

Loose Piece 



Reel AWG

mm² mm In. mm In.

4202

02-08-2004

02-08-2010

02-08-200

02-08-2009

14-20

2.00-0.50

1.52- . 0

.060-.1 0

.96-5.5

.156-.218

02-08-2006

02-08-2012

02-08-2005

02-08-2011

02-08-2008

02-08-2007

42024 02-08-1002

02-08-1006

02-08-1001

02-08-1005

14-20

2.00-0.50

1.52- . 0

.060-.1 0

.96-5.5

.156-.218

02-08-1004

02-08-1008

02-08-100

02-08-1007

Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab.

See Conditions on page 2

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 2C

INSULATION

CRIMP

▲

SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CRIMP HEIGHT

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 2 of 9

Revision: C Revision Date: 10-04-10

▲Insulation Crimp Note:

Due to the terminal’s insulation grip design

and/or insulation diameter range, this tool

uses “overlap” form geometry in the

insulation punch. This produces an overlap

insulation crimp (A620 – compliant). While

the insulation punch profile may appear

“lopsided”, this is a normal condition for this

tool. See figure to the right. (Some tools with

multiple crimp pockets may not have the

“overlap” profile on all pockets).

CONDITIONS:

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

Terminal

Series No.

Wire Size Conductor Crimp Insulation Crimp Pull Force

Minimum 



Profile

Height (Ref.) Width (Ref.)

Height (Ref.)

Width (Ref.)

AWG

mm2

mm In. mm In. mm In. mm In. N Lb. A

4202

14 2.00 1.55-1.65

.061-.065

2.71 .107 .24 .127 .1 .12 222.4

50.00

16 1. 0 1.40-1.50

.055-.059

2.50 .098 2.88 .11 .10 .122 1 .4

0.00

18 0.80 1. 0-1.40

.051-.055

2.24 .088 2.40 .094 2.8 .111 88.9 20.00

20 0.50 1. 0-1.40

.051-.055

2.2 .088 2. 8 .09 2.79 .110 57.8 1 .00

42024

14 2.00 1.55-1.65

.061-.065

2.71 .107 .24 .127 .1 .12 222.4

50.00

16 1. 0 1.40-1.50

.055-.059

2.50 .098 2.88 .11 .10 .122 1 .4

0.00

18 0.80 1. 0-1.40

.051-.055

2.24 .088 2.40 .094 2.8 .111 88.9 20.00

20 0.50 1. 0-1.40

.051-.055

2.2 .088 2. 8 .09 2.79 .110 57.8 1 .00

 To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:

Profile A: 2. 0- . 0mm (.090-.1 0 inch)

Profile B: 1.90-2.90mm (.075-.114 inch)

Profile C: 1.52-2.70mm (.060-.106 inch)

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 on this page.

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:

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page of 9

Revision: C Revision Date: 10-04-10

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

SWING OPEN

LOCATOR

LOCATOR TERMINAL IN PLACE

Figure 4

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

Anvils and Punches Installation

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

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

Figure 1.

Locator Installation and Removal

Follow the steps below to install or replace the locator. See 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. Swing the existing locator open and away from the hand tool.

. Firmly press down on the brass pivot shaft with your thumb, while pulling

the locator up. Slip the locator off the top of the brass pivot shaft.

Figure

LOCATOR

JAWS OPEN

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 4 of 9

Revision: C Revision Date: 10-04-10

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. Select the desired terminal listed in the preceding charts.

2. Swing the terminal locator away from the crimp tool shown in Figure

4. Some 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.

. When using the locator, press down on the wire stop on the locator

as shown in Figure 4. Insert the proper terminal into the proper nest

opening. Make sure when choosing the nest opening, it will

correspond with the A, B, or C profile on the hand tool.

4. Return the locator to its original position. Insert the proper wire over

the terminal. Some large O.D. wires may need to be placed into the

terminal before closing the tool. Gently touch the wire stop with the end of the wire. See Figure 5.

5. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

6. 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.

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

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

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.

. Visually inspect the crimped terminal for proper crimp

location.

Locator Replacement

See the parts list on the last page of this document for the

proper locator order number. Follow the steps below to

replace the locator.

1. Open the crimp hand tool.

2. Swing the existing locator open and away from the hand tool.

. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the

top of the brass pivot shaft. See Figure 6.

SWING

LOCATOR

OPEN

PRESS DOWN ON

BRASS PIVOT SHAFT

LIFT UP LOCATOR

JAWS OPEN

Figure 6

LOCATOR

IN PLACE

WIRE STOP

TERMINAL

WIRE AGAINST

STOP Figure 5

WIRE STOP

WIRE

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 5 of 9

Revision: C Revision Date: 10-04-10

4. Replace it with the proper locator by putting

over the brass pivot shaft and snapping it

into place.

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 fine

piece of equipment it needs cleaning and lubrication for a maximum service life of trouble free crimping. Use a

0 weight automotive (light) oil used at the oil points, every 5,000 crimps or months, shown in Figure 7A or

7B 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

pressing the ratchet release lever. See Figure 8.

How to Adjust Tool Preload (See Figure 8)

This hand tool is factory preset to 25-45 LBS.

preload. It may be necessary over the life of the

tool to adjust tool handle preload force. Listed

below are the steps required to adjust the crimping

force of the hand tool to obtain proper crimp

conditions:

1. Remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel.

2. Remove the locking screw with a 2mm hex wrench. The wrench set (6 810-0101), is not supplied. It is sold

separately from the hand tool.

. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase

handle force.

4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.

RATCHET

RELEASE LEVER

Figure 8

HANDLE

GRIP

REMOVED

ECCENTRIC AXLE

HANDLE

GRIP

LOCKING

SCREW

WRENCH SET

(SOLD

SEPERATELY)

PRELOAD

CHECK POINT

25.4MM

SETTING WHEEL

Figure 7B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 6 of 9

Revision: C Revision Date: 10-04-10

5. Replace the handle grip.

6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.

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: 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.

. Wear eye protection at all times.

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

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.

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

testing.

% If the tool does not meet minimum pull force values, handle preload should be increased and the pull test

rerun, (See How to Adjust Preload).

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

replaced.

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 7 of 9

Revision: C Revision Date: 10-04-10

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.

6 811-6870

6 810-0100

Hand Crimp Frame (Short) N/A N/A 9

6 810-0400

Hand Crimp Frame (Long) N/A N/A 9

6 816-0200

Battery Power Tool (110 V)

6 816-0 00 Power Crimp Head

6 816-0250

Battery Power Tool (220 V)

6 816-0 00 Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool Battery Powered Tool

Figure 9 Figure 10

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

Specification Sheet. See Chart above for the correct Manual or Specification Sheet.

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

BATTE

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING

KIT

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 8 of 9

Revision: C Revision Date: 10-04-10

RATCHET

RELEASE SCREW

Figure 11

M4 X 6mm

LONG BHCS

M4 X 12mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

M4 X 12mm

LONG BHCS

HAND TOOL PARTS LIST

Item Number Order Number Description Quantity

1 6 810-0100 Hand Crimp Frame (Short) 1

2 6 810-0101 Wrench Set (Not included) 0

6 810-0102 Locator Base 1

4 6 810-010 Repair Kit (Not included) 0

5 6 811-6870 Tool Kit with Locator 1

6 6 811-6875 Locator (only) REF

Tool Kit for MLX™ Pin and Socket Crimp Terminals

Doc No: ATS-6 81168HM Release Date: 09-18-06 UNCONTROLLED COPY Page 9 of 9

Revision: C Revision Date: 10-04-10

Figure 12

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

6 816-0 00 6 816-0 00 Power Crimp Head 1

6 811-6870 6 811-6870 Tool Kit 1

http://www.molex.com

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