molex 63811-1500 User manual

Hand Crimp Tool for Mini-Fit Sr. ™ Crimp Terminals
Doc No: ATS-638111500 Release Date: 08-13-01 UNCONTROLLED COPY Page 1 of 4
Revision: F Revision Date: 04-23-08
INSULATION
GRIP AREA
BELL MOUTH
WIRE
INSULATION
CONTACT GAP
0.00mm - 0.05mm
SEAM
INSULATION GAP
0.00mm ±
±±
±1.00 Max.
3.75mm ±
±±
±.20 3.75mm
±
±±
±
.20
CONTAC
T GAP
1.00mm ±
±±
±.20
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811-1500
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
SCOPE
Products: 10.00 mm (.394”) Pitch Mini-Fit Sr. ™ Crimp Terminals, 8 AWG.
Terminal Order No. Wire Size ● Insulation Diameter Strip LengthTerminal
Series No.
Loose Piece  Reel AWG mm² mm In. mm In.
42815-0030 42815-0031
42815 42815-0032
42815-0038
8 8.50 5.00-6.75 .197-.266 9.00-10.00 .354-.394
42817-0030 42817-0031
42817-0032 42817-0038
42817-0130 42817-0131
42817
42817-0132
8 8.50 5.00-6.75 .197-.266 9.00-10.00 .354-.394
 Customer to cut off terminal from reel: 0.5mm (.020”) maximum Cut-off Tab.
● On Mini-Fit Sr. ™ 8 AWG applications the insulation is stripped in both the conductor and insulation grips.
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 4B

Hand Crimp Tool for Mini-Fit Sr. ™ Crimp Terminals
Doc No: ATS-638111500 Release Date: 08-13-01 UNCONTROLLED COPY Page 2 of 4
Revision: F Revision Date: 04-23-08
CONDITIONS:
After crimping, the crimp profiles should measure the following (see notes on page 3).
Conductor Crimp Insulation Crimp
Wire Size Height (Ref) Width (Ref) Width (Ref)
Pull Force
Minimum Profile
Terminal
Series No. AWG
mm
2mm In. mm In. mm In. N Lb. 8
42815 8 8.50 3.20-3.30 .126-.130 3.90 .154 N/A N/A 400.0 90.00 X
42817 8 8.50 3.20-3.30 .126-.130 3.90 .154 N/A N/A 400.0 90.00 X
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. Place the terminal into the correct die profile (8) until the
terminal stopped by the locator.
2. Partially close the tool until the terminal is held in place.
3. Place a pre-striped wire into the terminal and align the
wire with the conductor and insulation grips visually. See
Figure 1.
4. Close the tool until the ratchet releases.
5. Carefully remove the crimped terminal.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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 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.
Figure 1
CONDUCTOR
GRIPS
WIRE
LOCATOR
TERMINAL

Hand Crimp Tool for Mini-Fit Sr. ™ Crimp Terminals
Doc No: ATS-638111500 Release Date: 08-13-01 UNCONTROLLED COPY Page 3 of 4
Revision: F Revision Date: 04-23-08
Miscrimps or Jams (See Figure 3)
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 slotted screw on the locator (back) side of the hand tool. See
Figure 3.
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.
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.
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable. 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. Refer to Molex Quality Crimping Handbook 63800-0029 for additional
information on crimping and crimp testing.
6. Molex does not certify crimp hand tools.
7. Hand held crimping tools are intended for low volume, prototyping, or repair requirements only.
CAUTION: Repetitive use of this tool should be avoided.

Hand Crimp Tool for Mini-Fit Sr. ™ Crimp Terminals
Doc No: ATS-638111500 Release Date: 08-13-01 UNCONTROLLED COPY Page 4 of 4
Revision: F Revision Date: 04-23-08
RATCHET
RELEASE SCREW
M2.5 WASHER
1
Figure 3
M2.5 X 4mm
LONG BHCS
PARTS LIST
Item Number Order Number Description Quantity
1 63811-1575 Locator 1
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
[email protected]
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
[email protected]
European Headquarters
Munich, Germany
49-89-413092-0
[email protected]
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: [phone]
Visit our Web site at http://www.molex.com