molex 63811-7100 User manual

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 1 of 10
Revision: D Revision Date: 01-31-14
Application Tooling
Specification Sheet
Tool Kit
Order No. 6 811-7170
Hand Crimp Tool
Order No. 6 811-7100
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: .093” Pin and Socket 14-18 AWG and 24-30 AWG and Claspcon™ Crimp Terminal Socket 24-30 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size



Insulation Diameter
Strip Length
Loose Piece



Reel
AWG
mm²
mm
In.
mm
In.
1433
39
-
00
-
0316
39
-
00
-
0320
39
-
00
-
0315
39
-
00
-
0319
24-28 - 0.80-1.50 .031-.059 3. 0-4.20 .146-.165
39
-
00
-
0318
39
-
00
-
0322
39
-
00
-
031
39
-
00
-
0321
02
-
09
-
1141
02
-
09
-
514
02
-
09
-
1142
24-30 - 0. 6-1.52 .030-.060 3.96-5.53 .156-.218
02
-
09
-
1144
02
-
09
-
5
146
1434
39
-
00
-
0324
39
-
00
-
0326
39
-
00
-
0323
39
-
00
-
0325
24
-
28
-
0.80
-
1.50
.031
-
.059
3. 0
-
4.20
.146
-
.165
02
-
09
-
2143
02
-
09
-
2141
02
-
09
-
6144
24-30 - 0. 6-1.52 .030-.060 3.96-5.53 .156-.218
02
-
09
-
6145
02
-
09
-
2149
1881
-
3
02
-
08
-
1104
02
-
08
-
1103
24
-
30
-
0. 6
-
1.52
.030
-
.060
3.96
-
5.53
.156
-
.218
424
02
-
09
-
1615
14
-
18
-
2.36
-
3.55
.093
-
.140
3.96
-
5.53
.156
-
.218
424 8
02
-
09
-
2612
02
-
09
-
2611
14
-
18
-
2.36
-
3.55
.093
-
.140
3.96
-
5.53
.156
-
.218

Follow the Cut
-
Off Tab specifications listed
in Crimp Spe
cification below
.
Terminals series 1433, 1434, and 1881 cannot be removed from the reel by manual cutting.
An applicator must be used or the terminals will not fit the housing properly.
See Conditions on page 3.
Crimp Specifications
Terminal Series No. 


Cut
-
off Tab Maximum
mm
In.
424
0.25
.010
424 8
0.25
.010
TYPE 2C

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 2 of 10
Revision: D Revision Date: 01-31-14
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
▲Insulation Crimp Note:
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 (A620 – 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:
After crimping, the conductor profiles should measure the following (See notes below).
Terminal Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum Profile
Height (Ref) Width (Ref)
Height (Ref)
Maximum Width (Ref)
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
A
B
C
1433
(39-00-XXXX)
24
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.35
.053
1.90
.0 5
29.4
6.60
X
26
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.32
.051
1.90
.0 5
19.6
4.40
X
28
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.28
.050
1.90
.0 5
9.8
2.20
X
1433
(02-09-XXXX)
24
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.35
.053
1.90
.0 5
3
5.6
8.00
X
26
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.32
.051
1.90
.0 5
22.2
5.00
X
28
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.28
.050
1.90
.0 5
13.3
3.00
X
30
-
0.84
-
0.91
.033
-
.036
1.60
.063
1.28
.050
1.90
.0 5
8.9
2.00
X
1434
(39-00-XXXX)
24
-
0.86
-
0.
94
.034
-
.03
1.60
.063
1.35
.053
1.90
.0 5
29.4
6.60
X
26
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.32
.051
1.90
.0 5
19.6
4.40
X
28
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.28
.050
1.90
.0 5
9.8
2.20
X
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CRIMP HEIGHT
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 3 of 10
Revision: D Revision Date: 01-31-14
Terminal Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum Profile
Height (Ref) Width (Ref)
Height (Ref)
Maximum Width (Ref)
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
A
B
C
1434
(02-09-XXXX)
24
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.35
.053
1.90
.0 5
35.6
8.00
X
26
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.32
.051
1.90
.0 5
22.2
5.00
X
28
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.28
.050
1.90
.0 5
13.3
3.00
X
30
-
0.84
-
0.91
.033
-
.036
1.60
.063
1.28
.050
1.90
.0 5
8.9
2.00
X
1881-3
24
-
0
.86
-
0.94
.034
-
.03
1.60
.063
1.35
.053
1.90
.0 5
44.5
10.00
X
26
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.32
.051
1.90
.0 5
26.
6.00
X
28
-
0.86
-
0.94
.034
-
.03
1.60
.063
1.28
.050
1.90
.0 5
13.3
3.00
X
30
-
0.84
-
0.91
.033
-
.036
1.60
.063
1.28
.050
1.9
0
.0 5
6.
1.50
X
424
14
-
1.85
-
1.96
.0 3
-
.0
2.49
.098
3.28
.129
4.85
.191
222.4
50.00
X
16
-
1.40
-
1.50
.055
-
.059
2. 5
.108
3.80
.150
3. 0
.146
1 .9
40.00
X
18
-
1.30
-
1.40
.051
-
.055
2. 5
.108
3. 5
.148
3. 0
.146
115.
26.00
X
424 8
14
-
1.85
-
1.96
.0 3
-
.0
2.49
.098
3.28
.129
4.60
.181
222.4
50.00
X
16
-
1.40
-
1.50
.055
-
.059
2. 5
.108
3.80
.150
3. 0
.146
1 .9
40.00
X
18
-
1.30
-
1.40
.051
-
.055
2. 5
.108
3. 5
.148
3. 0
.146
115.
26.00
X

To Achieve IPC
-
A
-
620 Class 2 Crimps, the
following over
-
all wire insulation diameter ranges are recommended:
1. Profile A: 0. 6-1.52mm (.030-.060 inch)
2. Profile B: 2. 9-3.55mm (.110-.140 inch)
3. Profile C: 2.36-3.14mm (.093-.124 inch)
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.
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 performed 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.
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.

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 4 of 10
Revision: D Revision Date: 01-31-14
ANVILS
POWER
CRIMP
HEAD
Figure
1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure
2
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.
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 4.
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
LOCATOR
JAWS OPEN
TERMINAL
PUSH HERE
TO OPEN
WIRE STOP
SWING OPEN
LOCATOR
LOCATOR
TERMINAL
IN PLACE
Figure 4

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 5 of 10
Revision: D Revision Date: 01-31-14
3. When using the locator, press down on the wire stop on the locator as
shown in Figure 4. Insert the proper terminal into the proper nest
opening. Make sure when choosing the nest opening, it will correspond
with the A, B, or C profile on the hand tool.
4. Return the locator to its original position. 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 5.
5. Compress the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. Release handles to open the
jaws.
6. 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.
. 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.
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.
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 6.
4. Replace it with the proper locator by putting over the
brass pivot shaft and snapping it into place.
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.
SWING
LOCATOR
OPEN
PRESS DOWN ON
BRASS PIVOT SHAFT
LIFT UP LOCATOR
JAWS OPEN
Figure 6
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE AGAINST
STOP
Figure 5
WIRE STOP
WIRE

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 6 of 10
Revision: D Revision Date: 01-31-14
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.
Use a 30 weight automotive (light) oil used at
the oil points, every 5,000 crimps or 3
months, shown in Figure A or B 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
pressing the ratchet release lever. See Figure 8.
How to Adjust Tool Preload (See Figure 8)
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.
RATCHET
RELEASE LEVER
Figure 8
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
Figure 7B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page of 10
Revision: D Revision Date: 01-31-14
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. mm (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.
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.

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 8 of 10
Revision: D Revision Date: 01-31-14
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.
63811- 1 0
6381
0
-
0100
Hand Crimp Frame (Short)
N/A
N/A
9
6381
0
-
04
0
0
Hand Crimp Frame (Long)
N/A
N/A
9
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp Head
10
63816
-
0250
Battery Powe
r
Tool (220 V)
63816
-
0300
Power Crimp Head
10
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure
9
Figure
10
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING
KIT

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 9 of 10
Revision: D Revision Date: 01-31-14
RATCHET
RELEASE SCREW
Figure 11
1
6
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
5
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810
-
0100
Hand Crimp Frame (
Short
)
1
2
63810
-
0101
Wrench Set (Not included)
0
3
63810
-
0102
Locator Base
1
4
63810
-
0103
Repair Kit (Not included)
0
5
63811
-
1 0
Tool Kit with
Locator
1
6
63811
-
1 5
Locator (only)
REF

Tool Kit for Claspcon™ and Pin and Socket Crimp Terminals
Doc No: ATS-63811 1HM Release Date: 02-12-0 UNCONTROLLED COPY Page 10 of 10
Revision: D Revision Date: 01-31-14
Figure 12
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
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
63811- 1 0 63811- 1 0 Tool Kit 1
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