molex 63811-5600 Manual de usuario
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
4
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
OR
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
9
63816-0250
Battery Power Tool (220 V)
63816-0300 Power Crimp Head
9
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
2
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
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
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item Order No Engineering No. Description Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63811-5670 63811-5670 Tool Kit 1
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