molex 63811-9200 User manual
Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals
Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 1 of 6
Revision: E Revision Date: 01 28 10
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811- 200
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
A precision user friendly terminal locator wire stop holds terminals in the proper crimping position
This tool is WHMA IPCA620 Class 3 only with specified wire types and RoHS compliant
SCOPE
Products: 0.60mm (.027") CP0.6 Female Crimp Terminals for CMC connector 18 20 AWG and 0.50 0.75mm2.
Terminal Order No. Wire Size Insulation Diameter Strip Length
Terminal Series No.
Available in Reel form only AWG mm² mm In. mm In.
18 1.91 2.06 .075 .081 3.50 .138
0.75 1.60 1.80 .063 .071 3.50 .138
0.60 1.75 1.90 .069 .075 3.50 .138
20 1.70 1.85 .067 .073 3.50 .138
98913 64322
98913 1029
98913 1219
98913 1319
98913 1339
98913 1039
98913 1239
98913 1359
64322 1029
64322 1219
64322 1319
64322 1339
64322 1039
64322 1239
64322 1359 0.50 1.40 1.50 .055 .059 3.50 .138
Follow the Cut Off Tab specifications on the Applicator specification sheets.
Note: Terminal will accommodate the thin wall small insulation with the TXL type American wires
and the IR or ID type Metric wires.
DEFINITION OF TERMS
TYPE 7
Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals
Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 2 of 6
Revision: E Revision Date: 01 28 10
CRIMP SPECIFICATION
After crimping, the conductor profiles should measure the following (see notes on page 5).
Conductor Crimp Insulation Crimp
Wire Size Height (Ref.) Height (Ref.)
Pull Force
Minimum Profile
Terminal Series No.
AWG
mm2 mm In. mm In. N Lb. 18-20 AWG
0.6-0.75 0.50
18 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25
X
0.75 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25
X
0.60 1.00 1.06 .039 .042 1.80 1.95 .071 .077 80.0 18.00
X
20 1.00 1.06 .039 .042 1.80 1.95 .071 .077 75.0 16.90
X
98913
0.50 0.97 1.03 .038 .040 1.70 1.85 .067 .073 70.0 15.75
X
18 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25
X
0.75 1.02 1.08 .040 .043 1.80 1.95 .071 .077 90.0 20.25
X
0.60 1.00 1.06 .039 .042 1.80 1.95 .071 .077 80.0 18.00
X
20 1.00 1.06 .039 .042 1.80 1.95 .071 .077 75.0 16.90
X
64322
0.50 0.97 1.03 .038 .040 1.70 1.85 .067 .073 70.0 15.75
X
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as
damage can occur to the tool or die.
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. Position the terminal from the back of the hand tool up and
into the proper locator opening with the crimp barrels
centered over the anvils. See Figure 1. Make sure when
choosing the correct nest and locator opening, it will
correspond with the pocket marked with the wire size
profile on the hand tool.
3. Partially close the jaws of the hand tool by squeezing the
handles until you hear the fist click of the ratchet. This will
move the wire stop into position.
4. From the front of the hand tool insert the pre stripped wire
over the terminal and against the wire stop. See Figure 2.
5. 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.
Figure 1 LOCATOR
WIRE STOP
TERMINAL INSIDE
THE GROOVE
OF THE LOCATOR
BACK OF THE
HANDTOOL
Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals
Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 3 of 6
Revision: E Revision Date: 01 28 10
6. Remove the crimped terminal from the terminal locator.
7. Visually inspect the crimped terminal for proper crimp
location.
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.
Maintenance
It is recommended that each operator of the tool be made aware of, and responsible for, the following
maintenance steps:
1. Remove the plastic handles from the metal tool frame by
removing the screws and 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
fine piece of equipment it needs cleaning and lubrication for a
maximum service life of trouble free crimping. Light oil used at
the pivot 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.
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 up. See Figure 3.
WIRE
Figure 2
WIRE IS UP AGAINST
THE WIRE STOP
FRONT OF THE
HAND TOOL
TERMINAL
RATCHET
RELEASE LEVER
Figure 3
Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals
Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 4 of 6
Revision: E Revision Date: 01 28 10
NUMBERED ADJUSTMENT
WHEEL
Figure 4
TURN CLOCKWISE (CW) OR
COUNTER CLOCKWISE (CCW)
TO ADJUST THE PRE-LOAD
TURN WITH A SMALL
SCREW DRIVER
REMOVE THE LOCKING 2MM SCREW
How to Adjust Tool 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 the 2mm locking screw from the numbered adjusting wheel using a screw driver. See Figure 4.
2. Using the same screw driver turn the adjustment wheel to the next highest number.
Note: The uneven numbers are in clockwise (CW) direction and the even numbers are counter clockwise
(CCW).
3. Example: If the preload is set at number 5, then to increase the preload, turn the adjustment wheel until the 6th
position is located over the 2mm locking screw tapped hole. If it is necessary to move to the 7th position, then
the adjustment wheel should be turned counter clockwise (CCW) until the 7th position is over the 2mm locking
screw tapped hole.
4. Replace the 2mm locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Check the crimp specifications and conduct a pull test after tool handle preload force is adjusted. Repeat these
steps until the desired result is obtained.
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: Molex crimp specifications are valid only when used with Molex terminals and tooling.
Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals
Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 5 of 6
Revision: E Revision Date: 01 28 10
CAUTIONS:
1. Manually powered hand tools are intended for low volume, prototyping, 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.
Certification
Molex does not certify or re certify 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.
Hand Crimp Tool for 0.60mm (.027") CP 0.6 Series Crimp Terminals
Doc No: ATS 638119200 Release Date: 02 12 07 UNCONTROLLED COPY Page 6 of 6
Revision: E Revision Date: 01 28 10
1
Figure 5
M3 X 6LG
BHCS
2
3
4
PARTS LIST
Item Number Order Number Description Quantity
REF 63811- 200 Hand Crimp Tool Figure 5
1 63811 9275 Locator 1
2 11 11 0320 Spring (Ratchet) 1
3 63600 0479 Spring (Main) 1
4 69008 0972 Adjuster Wheel 1
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1 800 78MOLEX
Far East North Headquarters
Yamato, Kanagawa, Japan
81 462 65 2324
Far East South Headquarters
Jurong, Singapore
65 6 268 6868
European Headquarters
Munich, Germany
49 89 413092 0
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630 969 4550
Fax: 630 969 1352
Visit our Web site at http://www.molex.com
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