molex 35745 Series User manual

Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals
Doc No: TS-6381968HM Release Date: 7-23-10 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 10-13-10
TYPE 4A
INSULATION
CRIMP
▲
SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Application Tooling
Sp cification Sh t
Modular Crimp H ad
Ord r No. 63819-6870
Hand Crimp Tool
Ord r No. 63819-6800
FEATURES
% 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
% Modular Crimp Head is removable and can be use in the ir Powered Tool Order No.63816-0100,
accompanied by ir Powered Crimp dapter (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 dapter (Order No. 63816-0600).
SCOPE
Products: VersaBlade™ Industry standard .070" tab terminals, 20 – 22 WG
T rminal
S ri s No.
T rminal
Ord r No.
Wir Siz
Insulation Diam t r
Strip L ngth
IPC/WHMA-A620 T rminal 
Maximum
AWG mm² mm In. mm In. mm In.
35745 35745-0110 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 4.00-4.80 .157-.189
35746 35746-0110 35746-0111 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 4.00-4.80 .157-.189
35747 35747-0110 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 4.00-4.80 .157-.189
35748 35748-0110 35748-0111 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 4.00-4.80 .157-.189
To achieve optimum IPC- 620 insulation crimps, use this insulation OD range.
Overall insulation OD specification for terminal.
DEFINITION OF TERMS
This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.

Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals
Doc No: TS-6381968HM Release Date: 7-23-10 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 10-13-10
WIRE
INSULATION
PUNCH
TERMINAL
WIRE STOP BLADE
Figur 1
Figur 2
WIRE
TERMINAL
LOCATOR
INSULATION
PUNCH
INSULATION
ANVIL
WIRE STOP
BLADE
CONDUCTOR ANVIL
CONDUCTOR
PUNCH
▲Insulation Crimp Not :
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 ( 620 – 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:
fter crimping, the crimp profiles should measure the
following (see notes on page 3).
T rminal
S ri s No
Wir Siz Conductor Crimp (R f.) Insulation Crimp (R f.) Pull Forc
Minimum Profil
H ight Width H ight Width
AWG mm2 mm In. mm In. mm In. mm In. N Lb. 20 22
35745 20 0.50
1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 2.45 ..096 2.90 - 3.10 .114 - .122 58.7 13.2 X
22 0.35 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 2.25 .089 2.90 - 3.10 .114 - .122 39.1 8.8 X
35746 20 0.50
1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 2.45 ..096 2.90 - 3.10 .114 - .122 58.7 13.2 X
22 0.35 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 2.25 .089 2.90 - 3.10 .114 - .122 39.1 8.8 X
35747 20 0.50
1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 2.45 ..096 2.90 - 3.10 .114 - .122 58.7 13.2 X
22 0.35 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 2.25 .089 2.90 - 3.10 .114 - .122 39.1 8.8 X
35748 20 0.50
1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 2.45 ..096 2.90 - 3.10 .114 - .122 58.7 13.2 X
22 0.35 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 2.25 .089 2.90 - 3.10 .114 - .122 39.1 8.8 X
Τ
ΤΤ
Τ 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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals
Doc No: TS-6381968HM Release Date: 7-23-10 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 10-13-10
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 T rminals
1. Place the terminal into the correct die profile until the terminal stopped by the locator.
2. Bring the wire stop blade down; make sure the wire stop located behind the conductor grip.
3. Place a pre-striped wire into the terminal until the end of wire touching the wire stop. See Figure 2.
4. Close the tool until the ratchet releases, the tool handles will then spring open.
5. Carefully remove the crimped terminal.
Not : The tamper proof ratchet action will not release the tool until it has been fully closed.
Maint nanc
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 6.
Warranty
This tool is for electrical terminal crimping purposes only. This tool is made of the best quality materials. ll vital
components are long life tested. ll 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. ny clamping,
fixturing, or use of handle extensions voids this warranty.
CAUTION: Repetitive use of this tool should be avoided.

Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals
Doc No: TS-6381968HM Release Date: 7-23-10 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 10-13-10
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.
Not s:
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.

Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals
Doc No: TS-6381968HM Release Date: 7-23-10 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 10-13-10
MODULAR
CRIMP
HEAD
BATTERY
POWER
B
E
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POW
ER
CRIMP
ADAPTER
Applications for th Modular Crimp H ad
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 ctuator 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.
The chart below shows all applications for this Modular Crimp Head.
Modular Crimp H ad
Ord r No.
Tool
Ord r no.
Tool
D scription
Adapt r
Ord r No.
Adapt r
D scription
Figur
No.
63819-6870
63816-0000 Hand Crimp Frame (Short) N/ N/ 3
63816-0050 Hand Crimp Frame (Long) N/ N/ 3
63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp dapter 4
63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp dapter 4
63816-0100 ir Power Tool 63816-0700 ir Power Crimp dapter 5
Applications for th Modular Crimp H ad
Hand Crimp Tool Batt ry Pow r d Tool Air Pow r d Tool
Figur 3 Figur 4 Figur 5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals
Doc No: TS-6381968HM Release Date: 7-23-10 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 10-13-10
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figur 6
M4 X 14mm
LONG BHCS
2
5
1
PARTS LIST
Hand Crimp Tool 63819-6800
It m Ord r Numb r D scription Quantity
1 63819-6870 Modular Crimp Head 1 (Ref)
2 63816-0050 Hand Crimp Frame (long) 1 (Ref)
3 63819-6875 Locator 1
4 63816-0001 Locking Pin 2
5 63600-0525 Handle Spring 1
6 63600-0520 Crimping Spring 2
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