molex 63811-4400 User manual

Hand Crimp Tool for MX150L™ Crimp Terminals
Doc No: ATS-6 81144HM Release Date: 04-05-04 UNCONTROLLED COPY Page 1 of 6
Revision: E Revision Date: 07-20-10
Application Tooling
Specification Sheet
Modular Crimp ead
Order No. 63811-4470
and Crimp Tool
Order No. 63811-4400
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
% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.6 816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 6 816-0700).
% Can also be used in the Battery Powered Tool Order No.6 816-0200 (110 V) or 6 816-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 6 816-0600).
SCOPE
Products: MX150L™ Crimp Terminals, 14-22 AWG.
Terminal
Series No.
Terminal Order No. Wire Size Insulation Diameter
Maximum Strip Length
Loose Reel AWG mm² mm In. mm In.
19417
19417-0047 19417-005 19417-0011 19417-0029
14-16 2.00-1.27 2.87- .5 .11 -.1 9 4.20-5.00 .165-.197 19417-0049 19417-0025 19417-00 1
19417-0051 19417-0027 19417-00
19417-0048 19417-0054 19417-0024 19417-00 0
18-22 0.8 -0. 6 2. 6-2.74 .09 -.108 4.20-5.00 .165-.197 19417-0050 19417-0026 19417-00 2
19417-0052 19417-0028 19417-00 4
19420
19420-0009 19420-0001 19420-0007
14-16 2.00-1.27 2.87- .5 .11 -.1 9 4.20-5.00 .165-.197
19420-0011 19420-000
19420-0010 19420-0002 19420-0008
18-22 0.8 -0. 6 2. 6-2.74 .09 -.108 4.20-5.00 .165-.197
19420-0012 19420-0004
TYPE 4A

Hand Crimp Tool for MX150L™ Crimp Terminals
Doc No: ATS-6 81144HM Release Date: 04-05-04 UNCONTROLLED COPY Page 2 of 6
Revision: E Revision Date: 07-20-10
INSULATION
CRIMP
BRUS
STRIP
LENGT
BELL MOUT
CRIMP EIG T
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
CRIMP SPECIFICATION
After crimping, the crimp profiles should measure the following (see notes on page 5).
Terminal
Series No.
Bell mouth Conductor Brush Bend up Bend Down Twist Roll
mm In. mm In. Degree Degree
19417 0.25-1.25 .010-.049 0.15-0.65 .006-.026 5 5 4 8
19420 0.25-1.25 .010-.049 0.15-0.65 .006-.026 5 5 4 8
Terminal
Series No.
Wire Size Conductor Crimp Ref. Insulation Crimp Ref. Pull Force
Minimum
Profile
AWG
eight Width eight Maximum Width
AWG
mm2 mm In. mm In. mm In. mm In. N Lb. 18-22 14-16
19417
14 2.00 1.45-1.55 .057-061 2.50 .098 .50 .1 8 4. 0 .169 222.6 50.00 X
16 1.27 1.45-1.55 .057-061 2.50 .098 .50 .1 8 4. 0 .169 1 .5 0.00 X
18 0.8 1.10-1.20 .04 -.047 2.00 .079 .50 .1 8 .40 .1 4 89.0 20.00 X
20 0.8 1.10-1.20 .04 -.047 2.00 .079 .50 .1 8 .40 .1 4 57.9 1 .00 X
22 0.8 1.10-1.20 .04 -.047 2.00 .079 .50 .1 8 .40 .1 4 5.6 8.00 X
19420
14 2.00 1.45-1.55 .057-061 2.50 .098 .50 .1 8 4. 0 .169 222.6 50.00 X
16 1.27 1.45-1.55 .057-061 2.50 .098 .50 .1 8 4. 0 .169 1 .5 0.00 X
18 0.8 1.10-1.20 .04 -.047 2.00 .079 .50 .1 8 .40 .1 4 89.0 20.00 X
20 0.58 1.10-1.20 .04 -.047 2.00 .079 .50 .1 8 .40 .1 4 57.9 1 .00 X
22 0. 6 1.10-1.20 .04 -.047 2.00 .079 .50 .1 8 .40 .1 4 5.6 8.00 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.

Hand Crimp Tool for MX150L™ Crimp Terminals
Doc No: ATS-6 81144HM Release Date: 04-05-04 UNCONTROLLED COPY Page of 6
Revision: E Revision Date: 07-20-10
Figure 2
CONDUCTOR
PUNC
WIRE
MALE LOCATOR
TERMINAL
INSULATION
PUNC
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
RETAINER
CONDUCTOR
PUNC
WIRE
FEMALE LOCATOR
TERMINAL
INSULATION
PUNC
INSULATION
ANVIL
CONDUCTOR
ANVIL
WIRE STOP
BLADE
RETAINER
Crimping Terminals
1. Select the proper locator on the locator assembly for the proper
terminal. The female locator is gray and is marked with an “F”. The
male locator is black and is marked with an “M”.
2. To position the desired locator, pull up on the knurled pin and turn
180° till the locator fits snuggly in the slot. See Figure , Assembly
Drawing.
. Lift the wire stop blade up.
4. Insert the terminal fully into the correct die profile and the locator slot
until the terminal is fully seated and stops.
5. Bring down the wire stop blade. Make sure the wire stop blade is fully
seated on the terminal behind the conductor grip section.
6. Slide the pre-stripped wire into the terminal; make sure to aim the
wire brush towards the tip point on the wire stop blade. See Figure 1. Align the wire so that it is parallel
and sitting into the terminal. Maintain a light and constant pressure on the wire that is seated in the
terminal at all times. (Do not let go of the wire.) Be sure to hold the wire and terminal in place until the
terminal is fully crimped. See Figure 2.
7. Close the tool until the ratchet releases.
8. Lift the wire stop blade up.
9. Carefully remove the crimped terminal.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.
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.
TERMINAL
PRE-
STRIPPED
WIRE
LOCATOR
Figure 1
WIRE STOP
BLADE

Hand Crimp Tool for MX150L™ Crimp Terminals
Doc No: ATS-6 81144HM Release Date: 04-05-04 UNCONTROLLED COPY Page 4 of 6
Revision: E Revision Date: 07-20-10
. 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 0 weight
automotive oil) used at the oil points, every 5,000 crimps or 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. All vital
components are long life tested. All tools are warranted to be free of manufacturing defects for a period of 0
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: Repetitive use of this tool should be avoided.
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.
. 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 for crimp height; however crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.
. 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 6 800-0029 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 MX150L™ Crimp Terminals
Doc No: ATS-6 81144HM Release Date: 04-05-04 UNCONTROLLED COPY Page 5 of 6
Revision: E Revision Date: 07-20-10
MODULAR
CRIMP
EAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP EAD
LOCKING
PINS
LOCKING
PINS
AIR POWER
CRIMP
ADAPTER
Applications for the Modular Crimp ead
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 Actuator 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 ead
Order No.
Tool
Order no.
Tool
Description
Adapter
Order No.
Adapter
Description
Figure
No.
6 811-4470
6 816-0000 Hand Crimp Frame (Short) N/A N/A
6 816-0050 Hand Crimp Frame (Long) N/A N/A
6 816-0200 Battery Power Tool (110 V) 6 816-0600 Battery Power Crimp Adapter 4
6 816-0250 Battery Power Tool (220 V) 6 816-0600 Battery Power Crimp Adapter 4
6 816-0100 Air Power Tool 6 816-0700 Air Power Crimp Adapter 5
Applications for the Modular Crimp ead
and Crimp Tool Battery Powered Tool Air Powered Tool
Figure 3 Figure 4 Figure 5
MODULAR
CRIMP
EAD
LOCKING
PINS
AND CRIMP
FRAME LONG
OR S ORT

Hand Crimp Tool for MX150L™ Crimp Terminals
Doc No: ATS-6 81144HM Release Date: 04-05-04 UNCONTROLLED COPY Page 6 of 6
Revision: E Revision Date: 07-20-10
RATC ET
RELEASE LEVER
ANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 6
2
5
1
MALE LOCATOR
(BLACK)
FEMALE
LOCATOR
(GRAY)
Pull and Turn to
Flip Locators
PARTS LIST
and Crimp Tool 63811-4400
Item Order Number Description Quantity
1 6 811-4470 Modular Crimp Head 1 (Ref)
2 6 816-0050 Hand Crimp Frame (Long) 1 (Ref)
6 811-4475 Locator 1
4 6 816-0001 Locking Pin 2
5 6 600-0525 Handle Spring 1
6 6 600-0520 Crimping Spring 2
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