0638119500 - Molex Inc. - Datasheet.Live

Hand Crimp Tool for OBD II 4.00mm (.157") Wire-to -Wire Crimp Terminal

Doc No: ATS-6381195HM Release Date: 08-03-07 UNCONTROLLED COPY Page 1 of 6

Revision: B Revision Date: 08-10-10

TYPE 4A

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63811-9570

Hand Crimp Tool

Order No. 63811-9500

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

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).

% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).

SCOPE

Products: OBD II 4.00mm (.157") Wire-to -Wire Crimp Terminal, 0.30-0.85mm² and 18-22 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size Actual mm²

Wire Type

Insulation Diameter Strip Length

mm In. mm In.

50420 50420-8100 (loose)

50420-8000 (reel) *

AVS-0.3, AVS-0.3f 0.37 JASO 1.60-1.90

.063-.075

3.00-3.70

.118-.146

22AWG 0.35 TXL 1.60-1.90

.063-.075

3.00-3.70

.118-.146

AVS-0.5, AVS-0.5f

AVSS-0.5, AVSS-0.5f

CAVS-0.5

0.56 JASO 1.60-2.10

.063-.083

3.00-3.70

.118-.146

20AWG 0.50 TXL 1.60-2.10

.063-.083

3.00-3.70

.118-.146

AVS-0.75f, AVSS-0.75f

0.79 JASO 1.80-2.30

.071-.090

3.00-3.70

.118-.146

AVS-0.85, AVSS-0.85

CAVS-0.85 0.88 JASO 1.80-2.30

.071-.090

3.00-3.70

.118-.146

18AWG 0.80 TXL 1.80-2.30

.071-.090

3.00-3.70

.118-.146

* Note: When using reeled parts, the cut-off tab must be maintained below 0.20mm (.008”)

Hand Crimp Tool for OBD II 4.00mm (.157") Wire-to -Wire Crimp Terminal

Doc No: ATS-6381195HM Release Date: 08-03-07 UNCONTROLLED COPY Page 2 of 6

Revision: B Revision Date: 08-10-10

INSULATION

CRIMP

▲

SEE NOTE

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.

▲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).

CRIMP SPECIFICATIONS:

After crimping, the conductor profile should measure the following.

Terminal

Series No.

Wire Size

Actual

mm²

Wire

Type

Conductor Profile AWG

Crimp Height (Ref.)

Crimp Width (Ref.)

0.3mm2

22 AWG

0.75+0.85mm2

18 AWG

0.5mm2

20 AWG

mm In. mm In.

50420

0.3, 0.3f 0.37 JASO

0.86-0.95

.034-.037

1.60 .063 X

22AWG 0.35 TXL 0.86-0.95

.034-.037

1.60 .063 X

0.5, 0.5f 0.56 JASO

0.96-1.06

.038-.042

1.60 .063 X

20AWG 0.50 TXL 0.96-1.06

.038-.042

1.60 .063 X

0.75f 0.79 JASO

1.10-1.17

.043-.046

1.60 .063 X

0.85 0.88 JASO

1.10-1.17

.043-.046

1.60 .063 X

18AWG 0.80 TXL 1.10-1.17

.043-.046

1.60 .063 X

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for OBD II 4.00mm (.157") Wire-to -Wire Crimp Terminal

Doc No: ATS-6381195HM Release Date: 08-03-07 UNCONTROLLED COPY Page 3 of 6

Revision: B Revision Date: 08-10-10

Terminal

Series No.

Wire Size

Actual mm²

Wire Type

Insulation Pull Force

Minimum

Crimp Height (Ref.)

Crimp Width (Ref.)

mm In. mm In. N Lb.

50420

0.3, 0.3f 0.37 JASO 2.20 .087 2.30 .091 58.8 13.2

22AWG 0.35 TXL 2.20 .087 2.30 .091 58.8 13.2

0.5, 0.5f 0.56 JASO 2.35 .093 2.40 .094 88.2 19.8

20AWG 0.50 TXL 2.35 .093 2.40 .094 88.2 19.8

0.75f 0.79 JASO 2.50 .098 2.60 .102 107.8

24.2

0.85 0.88 JASO 2.50 .098 2.60 .102 117.6

26.5

18AWG 0.80 TXL 2.50 .098 2.60 .102 117.6

26.5

ΤΤ

Τ 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.

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. Lift the wire stop blade up.

2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.

3. Bring down the wire stop blade.

4. Slide the pre-stripped wire into the wire stop blade. See Figure 1. Be sure to hold the wire in place until the

terminal is fully crimped. See Figure 2.

5. Close the tool until the ratchet releases, the tool handles will then spring open.

6. Lift the wire stop blade up if it is still in down position.

7. Carefully remove the crimped terminal.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

TERMINAL

PRE-

STRIPPED

WIRE

LOCATOR

Figure 1

WIRE STOP

BLADE

Figure 2

CONDUCTOR

PUNCH

WIRE

LOCATOR

TERMINAL

INSULATION

PUNCH

INSULATION

ANVIL

CONDUCTOR

ANVIL

WIRE STOP

BLADE

RETAINER

SPACER

Hand Crimp Tool for OBD II 4.00mm (.157") Wire-to -Wire Crimp Terminal

Doc No: ATS-6381195HM Release Date: 08-03-07 UNCONTROLLED COPY Page 4 of 6

Revision: B Revision Date: 08-10-10

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 lifting the ratchet release lever. See Figure 6.

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: Repetitive use of this tool should be avoided.

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.

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 63800-0029 for additional information on crimping and crimp testing.

Hand Crimp Tool for OBD II 4.00mm (.157") Wire-to -Wire Crimp Terminal

Doc No: ATS-6381195HM Release Date: 08-03-07 UNCONTROLLED COPY Page 5 of 6

Revision: B Revision Date: 08-10-10

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

6. Molex does not certify crimp hand tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Applications for the Modular Crimp Head

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

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.

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63811-9570

63816-0000

Hand Crimp Frame (Short) N/A N/A 3

63816-0050

Hand Crimp Frame (Long) N/A N/A 3

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool 63816-0700

Air Power Crimp Adapter 5

Applications for the Modular Crimp Head

Hand Crimp Tool Battery Powered Tool Air Powered Tool

Figure 3 Figure 4 Figure 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for OBD II 4.00mm (.157") Wire-to -Wire Crimp Terminal

Doc No: ATS-6381195HM Release Date: 08-03-07 UNCONTROLLED COPY Page 6 of 6

Revision: B Revision Date: 08-10-10

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 6

M4 X FLAT

WASHER

M4 X 14mm

LONG BHCS

PARTS LIST

Hand Crimp Tool 63811-9500

Item

Order Number

Description Quantity

1 63811-9570 Modular Crimp Head 1 (Ref)

2 63816-0050 Hand Crimp Frame (Long)

1 (Ref)

3 63811-9575 Locator 1

4 63816-0001 Locking Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

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