Hand Crimp Tool for Commoning Crimp Terminals HAND CRIMP TOOL Application Tooling Specification Sheet TYPE 4D Order No. 63825-0500 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: Commoning Terminals, 28-30 AWG. Terminal Order No. Wire Size Strip Length % Insulation Diameter Loose Piece + Reel AWG mm² mm In. mm In. 05-02-0092 05-02-0091 28-30 0.09-.055 0.90-0.80 .035-.031 3.96-5.54 .156-.218 + Customer to cut off terminal from reel: 0.18mm (.007”) maximum Cut-off Tab. % To Achieve IPC-A-620 Class 2 Crimps, the following wire insulation diameter limits are recommended: 1. 28 AWG 0.89mm (.035 inch) UL1061. 2. 30 AWG 0.81mm (.032 inch) UL1061. For Crimping 24-26 AWG Wire- Use 63823-1200 Hand Crimp Tool. Terminal Series No. 1457-6 DEFINITION OF TERMS INSULATION CRIMP BEND UP ROLLING BELL MOUTH SEAM BRUSH BEND DOWN STRIP LENGTH CUT-OFF TAB TWISTING CONDUCTOR CRIMP CONDUCTOR CRIMP HEIGHT Doc No: ATS-638250500 Revision: A Release Date: 02-14-11 Revision Date: 02-14-11 UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool for Commoning Crimp Terminals OVERLAP FORM GEOMETRY ▲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). PUNCH OVERLAP INSULATION CRIMP CONDITIONS: WIRE ANVIL After crimping, the conductor profiles should measure the following. Terminal Series No 1457-6 Wire Size AWG mm2 28 0.09 30 0.055 Conductor Crimp Height (Ref.) Width (Ref.) 0.89-0.91 .035-.036 1.10 .043 0.86-0.89 .034-.035 1.10 .043 Wire Size Terminal Series No 1457-6 AWG 28 30 mm2 0.09 0.055 Pull Force Minimum N Lb. 11.2 2.5 4.4 1.0 Insulation Crimp Height (Ref.) Width (Ref.) 1.65 Max .065 Max. 1.55 .061 1.65 Max .065 Max. 1.35 .053 Profile 28 X 30 X 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. HANDLE WILL SPRING OPEN 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. LOCATOR IN DOWN POSTION SQUEEZE HANDLES TOGETHER Crimping Terminals Figure 1 1. Select the desired terminal, listed in the preceding charts. Install the proper locator (See chart above PUSH ON THE and see Locator Installation on page 5). Figure 2 LOCATOR BUTTON 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. Doc No: ATS-638250500 Revision: A Release Date: 02-14-11 Revision Date: 02-14-11 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool for Commoning Crimp Terminals RELEASE LOCATOR BUTTON LOCATOR PUSHED THRU TOOLING TERMINAL TERMINAL LOCATOR BUTTON PUSHED IN TOOLING PARTIALLY CLOSED PARTIALLY CLOSE HANDLE Figure 3 3. While holding in the locator button, 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. 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. TERMINAL WIRE AGAINST THE WIRE STOP OPEN POSITION FIRST RATCHET POSITION Figure 4 WIRE STOP IS PART OF THE LOCATOR PRE-STRIPPED WIRE Figure 5 WIRE TERMINAL Note: The tamper proof ratchet action will not release the tool until it has been fully closed. WIRE 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. WIRE STOP Figure 6 TERMINAL Doc No: ATS-638250500 Revision: A Release Date: 02-14-11 Revision Date: 02-14-11 UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool for Commoning Crimp Terminals 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 Installation 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. LOCATOR SQUEEZE HERE SQUEEZE HERE JAWS OPEN MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION TOP SLOTS OF HANDTOOL PULL OPEN TOOLING TOOLING M3 BHCS TOP HOOKS Figure 8 Figure 7B PUSH ON HANDLE Figure 7A LOWER TABS 3. Lift and pull away from the hand tool. The top MATCH UP MARKS 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 Figure 9 shown in Figure 7B. 6. Holding onto the lower part of the locator with your FRONT BACK thumb and index finger, insert the locator 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 frame. Doc No: ATS-638250500 Revision: A Release Date: 02-14-11 Revision Date: 02-14-11 UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool for Commoning Crimp Terminals 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 along with the locator if using the left handed application. Follow the steps below: 1. The locator must be removed before reversing the tooling. LUBRICATION POINTS 2. Remove the M3 BHCS which is holding the upper tooling. (BOTH SIDES) LIGHT OIL 3. Flip the upper tooling to the opposite side and replace the M3 BHCS Make (EVERY 3 MONTHS OR 5,000 CRIMPS) 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 8 and 9. 4. Do the same thing with the lower tooling and tighten the M3 screws. Be sure Figure 10 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 RATCHET RELEASE significantly enhance the tool life. LEVER 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 Figure 11 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 11 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: Doc No: ATS-638250500 Revision: A Release Date: 02-14-11 Revision Date: 02-14-11 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool for Commoning Crimp Terminals 1. Hold the hand tool in the palm of your hand as shown in Figure 12. 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 counterclockwise (CCW) to increase handle force. The numbers will display higher. To decrease handle force, rotate 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. RATCHET RELEASE LEVER SQUEEZE THE LINK IN THE HANDLE HOLD THE HAND TOOL IN POSITION Figure 12 SETTING WHEEL 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. Doc No: ATS-638250500 Revision: A Release Date: 02-14-11 Revision Date: 02-14-11 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for Commoning Crimp Terminals PARTS LIST Item Number REF 1 2 3 Order Number 63825-0500 63825-0575 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 2 1 RATCHET RELEASE LEVER 3 Figure 13 http://www.molex.com Doc No: ATS-638250500 Revision: A Release Date: 02-14-11 Revision Date: 02-14-11 UNCONTROLLED COPY Page 7 of 7