molex 63811-8100 User manual

Hand Crimp Tool for 2.50mm (.098") Pitch Mini-Lock™ Crimp Terminals
Doc No: ATS-638118100 Release Date: 06-26-07 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 06-26-07
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
Specification Sheet
Order No. 63811-8100
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
 Right and Left handed applications
 This tool is WHMA-IPCA620 Class 2 compliant as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 2.50mm (.098") Pitch Mini-Lock™ Wire-to-Board Crimp Terminal, 22-28 AWG.
Terminal Order No. Wire Size Insulation Diameter Strip LengthTerminal
Series No.
Loose Piece  Reel AWG mm² mm In. mm In.
50351 50351-8100 50351-8000 22-28 0.33-0.08 1.10-1.70 .043-.067 2.30-2.80 .090-.110
 Follow the Cut-Off Tab specifications on Applicator specification sheets.
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
4D

Hand Crimp Tool for 2.50mm (.098") Pitch Mini-Lock™ Crimp Terminals
Doc No: ATS-638118100 Release Date: 06-26-07 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 06-26-07
TERMINAL
Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
CONDITIONS:
After crimping, the conductor profiles should measure the following.
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. 22-24
26-28
22 0.33 0.71-0.81 .028-.032 1.26 .050 1.77 .070 1.62 .064 39.2 8.82 X
24 0.20 0.71-0.81 .028-.032 1.26 .050 1.77 .070 1.62 .064 29.4 6.61 X
26 0.12 0.63-0.73 .025-.029 1.26 .050 1.66 .065 1.59 .062 19.6 4.41 X
50351
28 0.08 0.63-0.73 .025-.029 1.26 .050 1.66 .065 1.59 .062 9.8 2.20 X
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.
See Figure 1.
Crimping Terminals
1. Select the desired terminal listed in the
preceding charts.
2. Make sure the center of the locator is
in the down position. With the locator
attached, push the locator button on
the back of the hand tool to bring the
locator forward through the tooling.
See Figure 2.
3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the
wire gauge or terminal type markings on the hand tooling. See Figure 3.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure
1
LOCATOR
IN
DOWN POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2

Hand Crimp Tool for 2.50mm (.098") Pitch Mini-Lock™ Crimp Terminals
Doc No: ATS-638118100 Release Date: 06-26-07 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 06-26-07
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
PRE
-
STRIPPED
WIRE
TERMINAL
4. Release the locator button, allowing the locator to return to the
crimping position.
5. Close the tool handle until the first ratchet position engages. See
Figure 4.
6. Insert the properly stripped wire through the terminal and against the
wire stop. See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. Release the handles to
open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
8. Remove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
10. On some large O.D. wires, it may not be
possible to insert the wire with the tool partially
closed. Those wires should be inserted with the
hand tool in the open position. Insert the wire
above the terminal in the punch and against the
wire stop then close the tool. See Figure 6.
TERMINAL
Figure 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool for 2.50mm (.098") Pitch Mini-Lock™ Crimp Terminals
Doc No: ATS-638118100 Release Date: 06-26-07 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 06-26-07
Figure 11
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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
available, 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.
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. Squeeze gently on the lower area shown in Figure
7A with your thumb and index finger. The lower
tabs of the locator should disengage from the
hand tool.
3. Lift and pull away from the hand tool. The top
locator hooks should slip out of the top slots
easily. See Figure 7A.
4. To reinstall the new locator, make sure the hand
tool is in the open position.
5. Press the red insert down as far as it will go as
shown in Figure 7B.
6. Holding onto the lower part of the locator with your
thumb and index finger, insert the locators top
hooks (2) into the hand tool top slots.
7. Rotate the locator down and press the lower tabs
into the two bottom slots of the hand tool. To
secure the locator into place, the lower tabs must
snap into place on the hand tool the frame.
Right or Left Hand Operation
This hand tool has an added feature that can be
converted from a right handed application to a left
handed application. It is necessary to reverse the
tooling if using the left handed application along with
the locator. Follow the steps below:
SQUEEZE
HERE
LOCATOR
Figure 7
A
SQUEEZE
HERE
TOP
HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
MATCH
UP MARKS
FRONT
BACK
Figure 12

Hand Crimp Tool for 2.50mm (.098") Pitch Mini-Lock™ Crimp Terminals
Doc No: ATS-638118100 Release Date: 06-26-07 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 06-26-07
1. The locator must be removing before reversing the tooling.
2. Remove the M3 BHCS which is holding the upper tooling.
3. Flip the upper tooling to the opposite side and replace the M3 BHCS
Make sure the small markings on the front and back of the hand tool
frame match up and are on the outside of the hand tool frame. See Figure
11 and 12.
4. Do the same thing with the lower tooling and tighten the M3 screws. Be
sure the small markings line up.
5. Reinstall the locator by following the Instructions in the locator
replacement section.
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.
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 up on the ratchet release lever in the movable handle. See Figure
9.
How to Adjust Tool Preload (See Figure 10)
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. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link
towards the top of the hand tool frame. This will release the preload adjustment wheel.
2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the setting wheel clockwise (CW).
RATCHET
RELEASE
LEVER
Figure 9
LUBRICA
TION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 8

Hand Crimp Tool for 2.50mm (.098") Pitch Mini-Lock™ Crimp Terminals
Doc No: ATS-638118100 Release Date: 06-26-07 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 06-26-07
Figure 10
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
3. Release the link to lock the setting
wheel in place.
4. Check the crimp specifications or
conduct a pull test after tool handle
preload force is adjusted.
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 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 2.50mm (.098") Pitch Mini-Lock™ Crimp Terminals
Doc No: ATS-638118100 Release Date: 06-26-07 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 06-26-07
RATCHET
RELEASE LEVER
2
Figure
13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63811-8100 Hand Crimp Tool Figure 13
1 63811-8175 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
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Fax: [phone]
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