molex 63811-8300 User manual

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 1 of 10
Revision: A Revision Date: 05-16-07
INSULATIO
N
CRIMP
BRUS
H
STRIP
LENGTH
BELL
MOUTH
CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLIN
G
CONDUCTO
R
CRIMP
TWISTING
HAND CRIMP TOOL
Specification Sheet
Order No. 63811-8300
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: 3.50mm (.138") Pitch Crimp Terminal, 18-24 AWG UL1015 and UL1007 or
equivalent.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
50217
50217-8100
50217-8000
18-24
0.80-0.20
1.40-3.00
.055-.118
3.00-3.50
.118-.138
50217-9101
50217-9001
50539
50539-8100
50539-8000
18-24
0.80-0.20
1.40-3.00
.055-.118
3.00-3.50
.118-.138
50539-9101
50539-9001
Follow the Cut-Off Tab specifications on Applicator specification sheets.
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.
TYPE 4D

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 2 of 10
Revision: A Revision Date: 05-16-07
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal Series No
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum
Profile
Height (Ref.)
Width
(Ref.)
Height (Ref.)
Width
(Ref.)
AWG
mm2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
18-20
22-24
50217
18
0.80
1.02-1.12
.040-.044
1.80
.071
2.63
.103
2.82
.111
89.0
20.0
X
20
0.50
1.02-1.12
.040-.044
1.80
.071
2.63
.103
2.82
.111
57.9
13.0
X
22
0.35
0.87-0.97
.034-.038
1.93
.076
2.45
.096
2.30
.090
35.6
8.0
X
24
0.20
0.87-0.97
.034-.038
1.93
.076
2.45
.096
2.30
.090
22.3
5.0
X
50539
18
0.80
1.02-1.12
.040-.044
1.80
.071
2.63
.103
2.82
.111
89.0
20.0
X
20
0.50
1.02-1.12
.040-.044
1.80
.071
2.63
.103
2.82
.111
57.9
13.0
X
22
0.35
0.87-0.97
.034-.038
1.93
.076
2.45
.096
2.30
.090
35.6
8.0
X
24
0.20
0.87-0.97
.034-.038
1.93
.076
2.45
.096
2.30
.090
22.3
5.0
X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile 18-20: 3.00-1.75mm (.118-.069 inch)
Profile 22-24: 2.30-1.40mm (.090-.058 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. 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.
4. Release the locator button, allowing the locator to return to the crimping position.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR IN
DOWN
POSTION
PUSH ON THE
LOCATOR
BUTTON
Figure 2

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 3 of 10
Revision: A Revision Date: 05-16-07
TERMINAL
Figure 3
LOCATOR
PUSHED
THRU
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS PART
OF
THE LOCATOR
PRE-
STRIPPED
WIRE
TERMINAL
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.
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
TERMINAL
Figure 6
WIRE
WIRE
STOP
PARTIALLY
CLOSE
HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST
RATCHET
POSITION
OPEN
POSITIO
N

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 4 of 10
Revision: A Revision Date: 05-16-07
preformed to check hand tool crimp. Pull Force value Must exceed the Minimum pull force
specifications listed.

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 5 of 10
Revision: A Revision Date: 05-16-07
MATCH
UP MARKS
FRONT
BACK
Figure 12
Figure
11
PUSH ON
HANDLE
JAWS OPEN
PULL
OPEN
TOOLING
TOOLING
M3 BHCS
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:
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.
SQUEEZ
E
HERE
LOCATOR
Figure 7A
SQUEEZ
E
HERE
TOP
HOOKS
TOP SLOTS
OF
HANDTOOL
LOWER
TABS
MAKE SURE
CENTER OF
LOCATOR
IS IN THE
DOWN POSITION
Figure 7B

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 6 of 10
Revision: A Revision Date: 05-16-07
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.

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 7 of 10
Revision: A Revision Date: 05-16-07
Figure 10
SQUEEZE
THE LINK IN
THE
HANDLE
HOLD THE
HAND
TOOL IN
POSITION
SETTING
WHEEL
RATCHET
RELEASE
LEVER
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
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY 3 MONTHS
OR
5,000 CRIMPS)
Figure 8
RATCHET
RELEASE
LEVER
Figure 9

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 8 of 10
Revision: A Revision Date: 05-16-07
the setting wheel clockwise (CW).
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.

Hand Crimp Tool for 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 9 of 10
Revision: A Revision Date: 05-16-07
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 3.50mm (.138") Pitch Crimp Terminals
Doc No. ATS-638118300 Release Date: 05-16-07 UNCONTROLLED
COPY Page 10 of 10
Revision: A Revision Date: 05-16-07
RATCHET
RELEASE
LEVER
2
Figure
13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63811-8300
Hand Crimp Tool
Figure 13
1
63811-8375
Locator Assembly
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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