molex ServiceGrade User guide

Hand Crimp Tool Open Barrel Terminals
Doc No: ATS-638111000 Release Date: 06- 9-1 Page 1 of 4
Revision: B Revision Date: 10- -1
ServiceGrade
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
Hand Crimp Tool
Application Tooling
Specification S eet Order No. 63811-1000
FEATURES

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 Ergonomic soft grip handles for comfortable crimping with small handle spread
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 Accepts material thicknesses of 0.15 to 0.40mm and conductor barrel lengths of .00 to 3.50mm
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 Ideal for field repair and prototyping
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 Available in custom packaging for customer resale
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 Available through distribution only
SCOPE
Products: Molex Open Barrel Crimp Terminals, 14 to 4 AWG
CRIMPING INFORMATION:
Tool Profiles should be selected based on the wire AWG and insulation diameter.
Wire Size Conductor Tool
Section Range Pull Force Min. ▼
AWG
mm2
mm
in
N
Lb.
14
.00
.30
-
.50
.091
-
.098
.6
50.0
16
1.30
.00
-
.30
.079
-
.091
133.5
30.0
18
0.80
1.60
-
.00
.063
-
.079
89.0
0.0
0
0.50
1.40
-
1.80
.055
-
.071
57.9
13.0
0.35
1.40
-
1.60
.055
-
.063
35.6
8.0
4
0. 0
1.40
-
1
.40
.055
-
.055
.
5.0
▼
Each application should be verified for pull force.
Insulation
Diameter Range
Insulation Tool
Section Range
mm
in
mm
in
3.50
-
3.99
.138
-
0.157
3.90
-
4.80
.154
-
.189
3.00
-
3.50
.118
-
0.138
3.40
-
4.80
.134
-
.189
.49
-
3.00
.098
-
0.118
.80
-
3.90
.110
-
.154
.01
-
.49
.079
-
0.098
.30
-
3.40
.091
-
.134
1.50
-
.01
.059
-
0.079
1.80
-
.80
.071
-
.0140
0.99
-
1.50
.039
-
0.059
1.40
-
.00
.055
-
.079
3.99
-
4.50
.157
-
0.177
4.30
-
4.80
.169
-
.189
Restrictions:
Termination crimp quality is dependent on the conductor profile choice and skill of the operator. Customers should
independently verify that intended termination meets quality and performance needs. Not all terminal, wire and
profile combinations will provide minimum pull force requirements, or provide an acceptable crimp form.

Hand Crimp Tool Open Barrel Terminals
Doc No: ATS-638111000 Release Date: 06- 9-1 Page of 4
Revision: B Revision Date: 10- -1
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
DEFINITION OF TERMS
The illustration above is a generic representation of crimp attributes and not an exact image of a particular terminal.
OPERATION
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool.
WARNING: Make sure that the wire is DISCONNECTED from any power supply
Make sure work area is clean and dry and wear approved eye protection.
Crimping Terminals
1. Select the appropriate Molex terminal.
. Verify that the wire size, terminal material thickness and conductor barrel length are within the specifications
for this tool.
3. Strip the wire to the proper strip length.
4. Open the tool handles and insert the conductor grip area of the terminal into the desired conductor profile. See
Figure 1.
5. Squeeze the tool handles together enough to allow the terminal barrel to touch the top of the profile radii.
6. Align the insulation edge between the conductor and insulation
barrel and then insert the stripped wire into the terminal.
7. Verify that the conductor brush is present. If the wire does not fit
into the terminal, the conductor profile selection may be too
narrow.
8. Holding the wire in place, squeeze the tool handles firmly
together. Use two hands, if necessary.
9. After crimping, if any strands of wire are visible at the top of the
crimp form, the conductor profile selection chosen may be too
wide
10. Open the tool handles and insert the terminal into the desired
insulation section. Evaluate the housing opening before
crimping the insulation. See Figure .
Fig
ure
2
INSULATION
PUUNCH
TERMINAL
WIRE

Hand Crimp Tool Open Barrel Terminals
Doc No: ATS-638111000 Release Date: 06- 9-1 Page 3 of 4
Revision: B Revision Date: 10- -1
11. Gently squeeze the tool handles together to allow the terminal insulation profile to provide an acceptable strain
relief.
1 . Remove the crimped terminal from the tool. Inspect the crimp for loose wire strands, missing crimp, or other
damage. Any minor terminal bending may be straightened by hand.
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.
. 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. Light oil (such as SAE30W oil) applied at
the oil points, shown in Figure 4, every 5,000 crimps or 3 months, is
recommended.
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.
Warranty
This tool is for electrical terminal crimping purposes only. All tools are warranted to be free of manufacturing
defects for a period of 30 days. Should such a defect occur, the tool will be repaired or exchanged free of charge.
This 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.
ServiceGrade™ crimp hand tools are low cost tools used in field repair for a limited number of terminations. If a
high quality tool is required or a higher volume of terminations required, please purchase the corresponding
PremiumGrade™ crimp hand tool. A ServiceGrade™ crimp tool may or may not have a terminal locator and in
some case may need the locator removed to operate properly.
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.
. Insulated rubber handles are not protection against electrical shock. NEVER perform crimps on active
electrical circuits.
3. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
Fig
ure
3

Hand Crimp Tool Open Barrel Terminals
Doc No: ATS-638111000 Release Date: 06- 9-1 Page 4 of 4
Revision: B Revision Date: 10- -1
Certification
Molex does not certify or re-certify ServiceGrade™ hand tools but rather supplies the following guidelines for
customers to maintain their hand tools.
% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped
1 .7mm (1/ ”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
5mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull
testing.
% When the hand tool is no longer capable of achieving minimum pull force, it should be replaced.
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