molex 63811-8700 User manual

Hand Crimp Tool for SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 1 of 8
evision: C evision Date: 03-29-12
HAND CRIMP
TOOL
Application Tooling
Specification Sheet Order No 63811-8700
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
 ight and Left handed applications
 This tool is IPC/WHMA A-620 Class 2 compliant
 This tool is oHS compliant, however oHS compliant is not required
SCOPE
Products: SL™ Crimp Terminal, 22-24 and 32-36 AWG.
Terminal
Series No
Terminal Order No Wire Size 

Insulation Diameter Strip Length
Loose Piece 

Reel AWG mm² mm In mm In
50084 50084-8114
50084-8160 50084-8014 50084-8060
22-24 0.33-0.20 1.09-1.65 .043-.065 2.54-3.17 .100-.125
50084-8129 50084-8029
50088 50088-8114
50088-8160 50088-8014 50088-8060
22-24 0.33-0.20 1.09-1.65 .043-.065 2.54-3.17 .100-.125
50088-8128 50088-8028
70021
16-02-0114 40-08-0873 16-02-0081 16-02-0874
22-24 0.33-0.20 1.09-1.65 .043-.065 2.54-3.17 .100-.125 16-02-0115 70021-0114 16-02-0093 16-02-0107
16-02-0117 70021-0117 16-02-0116 70021-0081
16-02-0111 16-02-0113 16-02-0079 16-02-0092 32-36
0.03-0.01 0.43-0.64 .017-.025 2.54-3.17 .100-.125
16-02-0112 16-02-0080 16-02-0106
70058
16-02-0102 70058-0102 16-02-0086 70058-0086
22-24 0.33-0.20 1.09-1.65 .043-.065 2.54-3.17 .100-.125
16-02-0103 70058-0103 16-02-0087 70058-0087
16-02-0104 70058-0104 16-02-0088 70058-0088
16-02-0147 70058-4102 16-02-0131 70058-4086
16-02-0152 70058-5001
16-02-0099 16-02-0101 16-02-0074 16-02-0085
32-36 0.03-0.01 0.43-0.64 .017-.025 2.54-3.17 .100-.125 16-02-0100 70058-0099 16-02-0084 70058-0084
16-02-0144 70058-4099 16-02-0143 70058-4084
71851
16-02-1114 16-02-1125 16-02-1110 16-02-1124 22-24
0.33-0.20 1.09-1.65 .043-.065 2.54-3.17 .100-.125
16-02-1115 16-02-1111
16-02-1119 16-02-1123 16-02-1118 16-02-1122 32-36
0.03-0.01 0.43-0.64 .017-.025 2.54-3.17 .100-.125
16-02-1121 16-02-1120
Follow the Cut-Off Tab specifications on Applicator specification sheets
See Conditions on page 2
TYPE 4D

Hand Crimp Tool for SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 2 of 8
evision: C evision Date: 03-29-12
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
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.
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 22-24 32-36
50084
22 0.33 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 39.2 8.82 X
24 0.20 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 29.4 6.61 X
32 0.03 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 4.4 1.00 X
34 0.02 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 2.6 0.60 X
36 0.01 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 1.8 0.40 X
50088
22 0.33 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 39.2 8.82 X
24 0.20 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 29.4 6.61 X
32 0.03 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 4.4 1.00 X
34 0.02 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 2.6 0.60 X
36 0.01 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 1.8 0.40 X
70021
22 0.33 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 39.2 8.82 X
24 0.20 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 29.4 6.61 X
32 0.03 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 4.4 1.00 X
34 0.02 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 2.6 0.60 X
36 0.01 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 1.8 0.40 X
70058
22 0.33 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 39.2 8.82 X
24 0.20 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 29.4 6.61 X
32 0.03 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 4.4 1.00 X
34 0.02 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 2.6 0.60 X
36 0.01 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 1.8 0.40 X
71851
22 0.33 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 39.2 8.82 X
24 0.20 0.75-0.85 .030-.033 1.43 .056 1.70 .067 1.76 .069 29.4 6.61 X
32 0.03 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 4.4 1.00 X
34 0.02 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 2.6 0.60 X
36 0.01 0.53-0.63 .021-.025 0.91 .036 0.95 .037 1.16 .046 1.8 0.40 X
 To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
1. Profile 22-24: 1.09-1.65mm (.043-.065 inch)
2. Profile 32-36: 0.50-0.64mm (.020-.025 inch)

Hand Crimp Tool for SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 3 of 8
evision: C evision Date: 03-29-12
RELEASE
LOCATOR
BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING TERMINAL
LOCATOR
BUTTON
PUSHED IN
• 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.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
Note:
A crimp height chart is provided with this manual as eference 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 performed to check hand tool crimp. Pull Force value Must exceed
the Minimum pull force specifications listed.
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.
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. elease 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.
elease the handles to open the jaws.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
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 SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 4 of 8
evision: C evision Date: 03-29-12
Figure 5
TERMINAL
WIRE
AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART OF
THE LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
8. emove 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.
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. otate 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 frame.
TERMINAL
Figure 6
WIRE
WIRE STOP
SQUEEZE
HERE
LOCATOR
Figure 7A
SQUEEZE
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 SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 5 of 8
evision: C evision Date: 03-29-12
Figure 11
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
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 removed before reversing the
tooling.
2. emove 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. einstall 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. emove 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 8
MATCH
UP MARKS
FRONT BACK
Figure 12

Hand Crimp Tool for SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 6 of 8
evision: C evision Date: 03-29-12
Figure 10
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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. otate 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).
3. elease 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. epetitive 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.
RATCHET RELEASE
LEVER
Figure 9

Hand Crimp Tool for SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 7 of 8
evision: C evision Date: 03-29-12
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 SL™ Crimp Terminals
Doc No. ATS-638118700 elease Date: 07-30-07 UNCONTROLLED COPY Page 8 of 8
evision: C evision Date: 03-29-12
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
EF 63811-8700 Hand Crimp Tool Figure 13
1 63811-8775 Locator Assembly 1
2 63810-0104 Spring, eturn 1
3 63810-0105 Spring, atchet 1
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