molex 35745 Series User manual

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 1 of 9
Revision: C Revision Date: 09-17-10
Application Tooling
Specification Sheet
Tool Kit
Order No. 6 819-0770
Hand Crimp Tool
Order No. 6 819-0700
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 RoHS compliant.
SCOPE
Products: 1.80mm (.070”) Wide VersaBlade™ Wire –to-Wire Crimp Terminal, 18-20 AWG Doubles.
(wires placed 45° orientation).
Terminal Series No. Terminal Order No. Wire Size 

Insulation Diameter
Maximum Strip Length


Available in Reel form only AWG mm² mm in mm in
35745 35745-0310 (2) 18 (2) 0.80 (2) .118 (2) 3.00 4.00-4.80 .157-.189
(2) 20 (2) 0.50
35746 35746-0310 (2) 18 (2) 0.80 (2) .118 (2) 3.00 4.00-4.80 .157-.189
(2) 20 (2) 0.50
35747 35747-0310 (2) 18 (2) 0.80 (2) .118 (2) 3.00 4.00-4.80 .157-.189
(2) 20 (2) 0.50
35748 35748-0310 (2) 18 (2) 0.80 (2) .118 (2) 3.00 4.00-4.80 .157-.189
(2) 20 (2) 0.50
The terminals above are reeled parts only. Customer to cut off terminal from reel: 0.30mm (.012”) maximum.
See Conditions on Page 2.
TYPE 4C

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 2 of 9
Revision: C Revision Date: 09-17-10
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL
MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM
WIRES
SIDE BY SIDE
NO
YES
WIRES
STACKED
WIRES
AT 45°
°°
°
TERMINAL
WIRES AT 45
°
°°
°
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Wire Feeding Orientation
This Hand Tool and crimp was developed for 18-20 AWG Double wires in a 45° orientation. See the following
illustrations below.

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 3 of 9
Revision: C Revision Date: 09-17-10
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
CONDITIONS:
After crimping, the conductor profiles should measure the following (See notes below).
Terminal Series No. Wire Size Conductor Pull Force
Minimum Profile
Crimp Height (Ref) Punch Width (Ref)
AWG mm2 mm In. mm In. N Lb. A B
35745 (2) 18
(2) 0.80 1.45-1.55 .057-.061 3.00 .118 97.8 22.0 X
(2) 20 (2) 0.50 1.35-1.45 .053-.057 3.00 .118 58.7 13.2 X
35746 (2) 18
(2) 0.80 1.45-1.55 .057-.061 3.00 .118 97.8 22.0 X
(2) 20 (2) 0.50 1.35-1.45 .053-.057 3.00 .118 58.7 13.2 X
35747 (2) 18
(2) 0.80 1.45-1.55 .057-.061 3.00 .118 97.8 22.0 X
(2) 20 (2) 0.50 1.35-1.45 .053-.057 3.00 .118 58.7 13.2 X
35748 (2) 18
(2) 0.80 1.45-1.55 .057-.061 3.00 .118 97.8 22.0 X
(2) 20 (2) 0.50 1.35-1.45 .053-.057 3.00 .118 58.7 13.2 X
 Wires should be placed horizontally for double crimp.


 To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
1. Profile A: 2.00-2.80mm (.079-.110 inch)
2. Profile B: 1.70-2.50mm (.067-.098 inch)
Tool Qualification otes:
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.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 4 of 9
Revision: C Revision Date: 09-17-10
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR
TERMINAL
IN PLACE
Figure
LOCATOR LATCH
IN OPEN POSITION
Figure 5
WIRE IN TERMINAL
JAW
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCK
LATCH IN
UP RIGHT
POSITION
LOCATOR
CLOSED
Figure 4
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
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 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.
3. 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.
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.

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 5 of 9
Revision: C Revision Date: 09-17-10
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 3. 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. See 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 profile on the hand tool. See 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.
See 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.
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.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A
Figure 7B
Figure 6
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 6 of 9
Revision: C Revision Date: 09-17-10
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. See Figure 7A or 7B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams for Crimp Hand Tools Only
(See Figure 10)
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 rotating the small slotted screw marked with an arrow. See 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. Should 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 OT 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.
% 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.
% 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.

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 7 of 9
Revision: C Revision Date: 09-17-10
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.
63819-0770
63810-1050 Hand Crimp Frame (Short) /A /A 8
63810-1000 Hand Crimp Frame (Long) /A /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
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
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 8 of 9
Revision: C Revision Date: 09-17-10
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 63819-0770 Tool Kit with Locator 1
3 63811-4773 Locator Base 1
4 63819-0775 Locator (only) REF

Tool Kit for 1.80mm (.070”) Wide VersaBlade™ Crimp Terminals
Doc o: ATS-6381907HM Release Date: 08-29-07 UNCONTROLLED COPY Page 9 of 9
Revision: C Revision Date: 09-17-10
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
63819-0770 63819-0770 Tool Kit 1
http://www.molex.com