molex 63811-6400 User manual

Hand Crimp Tool for SPOX™ Terminals
Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 1 of 6
Revision: B Revision Date: 03-29-08
TYPE 2C
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63811-6400
FEATURES
 A full cycle ratcheting hand tool ensures complete crimps
 Ergonomic soft grip handles for comfortable crimping
 A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
 This tool is WHMA-IPCA620 Class 2 and RoHS compliant
SCOPE
Products: Pico-SPOX™ Crimp Female Terminal, 24-30 AWG.
Terminal Order No. Wire Size Wire Type
 Insulation Diameter
Maximum Strip Length
Terminal
Series No. Loose Piece
 Reel AWG mm² AWG Type mm In. mm In.
24 0.20 24 UL1061 1.15 .045 1.05-1.54 .041-.061
26 UL1061
28 UL1061
87421 87421-0000 26-30 0.12-0.05
30 UL1571
1.00 .039 1.05-1.54 .041-.061
 Customer to cut off terminal from reel: 0.29mm (.011”) maximum Cut-off Tab.
 See Conditions on page 2.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.

Hand Crimp Tool for SPOX™ Terminals
Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 2 of 6
Revision: B Revision Date: 03-29-08
TERMINAL
SWING OPEN
PRESS HERE ON LOCATOR
LOCATOR
TERMINAL IN PLACE
Figure 2
FRAME
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes on page 5).
Conductor Crimp Insulation Crimp
Wire Size Height (Ref.) Width (Ref.)
Height (Ref.) Width (Ref.)
Pull Force
Minimum
 Profile
Terminal Series No
AWG
mm
2mm In. mm In. mm In. mm In. N Lb. A B
87421 24 0.20 0.56-0.60 .022-.024 1.00 .039 1.40 .055 1.10 .043 29.4 6.60 X
87421 26 0.12 0.52-0.58 .020-.023 1.00 .039 1.24 .049 1.10 .043 19.6 4.40 X
87421 28 0.08 0.52-0.58 .020-.023 1.00 .039 1.24 .049 1.10 .043 9.8 2.20 X
87421 30 0.05 0.52-0.58 .020-.023 1.00 .039 1.24 .049 1.10 .043 6.7 1.50 X
 To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile A: 1.00-1.15mm (.039-.045 inch)
Profile B: 0.65-1.00mm (.025-.039 inch)
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
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. Select the desired terminal listed in the preceding charts.
2. Swing the terminal locator away from the crimp tool shown in
Figure 2. Gently press on the locator to open the wire stop.
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.
Figure 1
LOCATOR
JAWS OPEN

Hand Crimp Tool for SPOX™ Terminals
Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 3 of 6
Revision: B Revision Date: 03-29-08
SWING
LOCATOR
OPEN
PRESS DOWN ON
BRASS PIVOT SHAFT
LIFT UP
LOCATOR
JAWS
OPEN
Figure 4
3. When using the locator, swing the locator away from the crimp
tool, and gently press the locator against the tool frame as
shown in Figure 2. The wire stop will automatically open.
Insert the proper terminal into the proper nest opening. Make
sure when choosing the nest opening, it will correspond with
the A or B profile on the hand tool.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Some large O.D. wires
may need to be placed into the terminal before closing the tool.
Gently touch the wire stop with the end of the wire. See Figure
3.
6. Compress the terminal by squeezing the tool handles until the
ratchet mechanism cycle has been completed. Release
handles to open the jaws.
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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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 on page 2.
Locator Replacement
See the parts list on the last page of this document for the
proper locator order number. Follow the steps below to
replace 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. See Figure 4.
4. Replace it with the proper locator by putting over the brass pivot shaft and snapping it into place.
WIRE
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE STOP
WIRE
AGAINST STOP
Figure 3

Hand Crimp Tool for SPOX™ Terminals
Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 4 of 6
Revision: B Revision Date: 03-29-08
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
fine piece of 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, shown in Figure 6will
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 pressing the ratchet release lever. See Figure
6.
How to Adjust Tool Preload
(See Figure 6)
This hand tool is factory preset to 25-45 LBS.
preload. It may be necessary over the life of the
tool to adjust tool handle preload force. Listed
below are the steps required to adjust the
crimping force of the hand tool to obtain proper crimp conditions:
1. Remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel.
2. Remove the locking screw with a 2mm hex wrench. The wrench set (63810-0101), is not supplied. It is sold
separately from the hand tool.
3. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase
handle force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 5
RATCHET
RELEASE LEVER
Figure 6
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELO
AD
CHECK POINT
25.4MM
SETTING WHEEL

Hand Crimp Tool for SPOX™ Terminals
Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 5 of 6
Revision: B Revision Date: 03-29-08
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.
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.
%If the tool does not meet minimum pull force values, handle preload should be increased and the pull test
rerun, (See How To Adjust Preload).
%When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.

Hand Crimp Tool for SPOX™ Terminals
Doc No: ATS- 638116400 Release Date: 06-19-06 UNCONTROLLED COPY Page 6 of 6
Revision: B Revision Date: 03-29-08
PARTS LIST
Item Number Order Number Description Quantity
REF 63811-6400 Hand Crimp Tool Figure 7
1 63810-0101 Wrench Set (Not included) 0
2 63810-0102 Locator Base Assembly 1
3 63810-0103 Repair Kit (Not included) 0
4 63811-6475 Locator 1
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
[email protected]
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Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
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65-6-268-6868
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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
RATCHET
RELEASE LEVER
2
Figure 7
M4 X 5LG
BHCS
3
4
1
3