Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals TYPE 2C Application Tooling Specification Sheet Tool Kit Order No. 63819-3270 Hand Crimp Tool Order No. 63819-3200 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 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool. Many different Tool kits can be used with a single Battery Powered Tool. This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant. % SCOPE Products: Quick Disconnect, Female, Flag, for 0.50 and 0.80mm² (20 and 18 AWG) wires. Terminal Terminal Order No. Series No. Reel 94030 Wire Size Insulation Diameter Strip Length mm² mm In. mm In. 0.50 94030-5000 20 (0.52) 2.10-2.60 .083-.102 6.0-7.0 .236-.276 94030-5001 0.80 18 (0.82) Customer to cut off terminal from reel. Cut tab flush with terminal on both ends. AWG DEFINITION OF TERMS STRIP LENGTH SEAM CONDUCTOR CRIMP WIRE INSULATION CRIMP Doc No: ATS-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 UNCONTROLLED COPY Page 1 of 8 Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals CONDITIONS: After crimping, the conductor profiles should measure the following (see notes below). Terminal Series No. 94030 Terminal Series No. 94030 Wire Size AWG mm2 0.50 20 (0.52) 0.80 18 (0.82) Wire Size AWG mm2 0.50 20 (0.52) 0.80 18 (0.82) Conductor Crimp Profile Height (Ref.) Width (Ref.) mm In. mm In. A B 1.40 - 1.50 .055 - .059 2.35 .093 X 1.40 - 1.50 .055 - .059 2.35 .093 X 1.50 – 1.60 .059 - .063 2.35 .093 X 1.50 – 1.60 .059 - .063 2.35 .093 X Insulation Crimp Height (Ref.) Width (Ref.) mm In. mm In. 2.80 – 2.90 .110 - .114 3.45 max .136 max 2.80 – 2.90 .110 - .114 3.45 max .136 max 2.90 – 3.00 .114 - .118 3.45 max .136 max 2.90 – 3.00 .114 - .118 3.45 max .136 max Pull Force Minimum N Lb. 78.45 17.6 78.45 17.6 117.68 26.4 117.68 26.4 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. 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, 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. CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can occur to the tool or die. POWER CRIMP HEAD INSTALLATION To install the Tool Kit into the Power Crimp Head follow the steps below: PUNCHES M4 X 18 LONG BHCS Anvils and Punches Installation 1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place. 2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See Figure 1. M4 X 10 LONG BHCS ANVILS Doc No: ATS-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 UNCONTROLLED COPY Figure 1 Page 2 of 8 Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals KNURLED FASTENER OPERATION JAWS OPEN 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. UPPER TOOLING Crimping Terminals TERMINAL 1. Select the desired terminal listed in the preceding charts. 2. Before attempting to crimp any terminals, make sure all the upper tooling is correctly placed into the upper jaw. The desired nest being used for the proper wire size should be in the forward position, (The marking on the upper tooling “A” for 0.8mm ² or “B” Figure 2 for 0.5mm²). This is done by removing the knurled fastener that holds the upper tooling in place and then rotating it 180° to the correct position. Then, re-installing the fastener. See Figure 2. 3. Place the terminal into the nest profile, centered on the nest as shown, with the outer edges of the crimp grips flush with each side of the crimp die and the opening in the terminal centered below the forward leg of the right punch. See Figure 3. 4. Partially close the tool until the terminal is held in place and re-position the terminal as necessary. 5. From the left side of the tool, insert the pre-stripped wire into the terminal until the conductor is centered, front to rear, in the crimp grips. See Figure 3. 6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release handles to open the jaws. Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 7. Remove the crimped terminal. Inspect for proper crimp location, and check for insulation closure. For the Battery Power Tool: 1. Cycle the Battery Power Tool to crimp the terminal to the wire. 2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on the wire. The terminal locator can be in either position. 3. Visually inspect the crimped terminal for proper crimp location. CONDUCTOR OF THE TERMINAL CENTERED IN CRIMP GRIPS FRONT TO REAR SEE NOTE BELOW SEE NOTE BELOW WIRE 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. Doc No: ATS-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 Figure 3 Note: The Terminal should be centered in crimp nests with the outer edges of the crimp grips flush with the jaws on both sides. UNCONTROLLED COPY Page 3 of 8 Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals 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 fine piece of equipment it needs cleaning and lubrication for a maximum service life of LUBRICATION trouble free crimping. Use a 30 weight POINTS (BOTH SIDES) automotive (light) oil used at the oil LIGHT OIL points, every 5,000 crimps or 3 months, (EVERY MONTH shown in Figure 4A or 4B will significantly OR enhance the tool life. 5,000 CRIMPS) 4. Wipe excess oil from hand tool, Figure 4A 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 the ratchet release lever. See Figure 5. Figure 4B PRELOAD CHECK POINT 25.4MM SETTING WHEEL ECCENTRIC AXLE HANDLE GRIP REMOVED How to Adjust Tool Preload (See Figure 5) This hand tool is factory preset to 25-45 LBS. WRENCH SET (SOLD preload. It may be necessary over the life of the SEPERATELY) 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: LOCKING SCREW HANDLE GRIP RATCHET RELEASE LEVER Figure 5 1. Remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel. 2. Remove the locking screw with a 2mm hex wrench. The wrench set (63810-0101), is not supplied. It is sold separately from the hand tool. 3. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase handle force. 4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw. 5. Replace the handle grip. 6. 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 Doc No: ATS-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 UNCONTROLLED COPY Page 4 of 8 Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals 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 commercial grade 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-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 UNCONTROLLED COPY Page 5 of 8 Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals The chart below shows all applications for this Tool Kit. Adapter Figure Tool Tool Power Head Order No. Description No. Order no. Description 63810-0100 Hand Crimp Frame (Short) N/A N/A 6 63810-0400 Hand Crimp Frame (Long) N/A N/A 6 63819-3270 63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head 7 63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head 7 Tool Kit Order No. Applications for the Tool Kit Hand Crimp Tool Battery Powered Tool POWER CRIMP HEAD TOOLING KIT TOOLING KIT HAND CRIMP FRAME LONG AND SHORT BATTERY POWERED TOOL Figure 6 LOCKING PINS Figure 7 WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper instruction and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See Chart above for the correct Manual or Specification Sheet. WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the power is turned off. 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. Doc No: ATS-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 UNCONTROLLED COPY Page 6 of 8 Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals HAND TOOL PARTS LIST Item Number 1 2 3 4 Order Number 63810-0100 63810-0101 63810-0103 63819-3270 Description Hand Crimp Frame (Short) Wrench Set (Not included) Repair Kit (Not included) Tool Kit Quantity 1 0 0 1 2 3 1 RATCHET RELEASE SCREW 4 3 M4 X 12mm LONG BHCS Doc No: ATS-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 KNURLED FASTENER UNCONTROLLED COPY Figure 8 Page 7 of 8 Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals POWER HEAD PARTS LIST Item 1 2 Order No 63816-0300 63819-3270 Engineering No. 63816-0300 63819-3270 Description Power Crimp Head Tool Kit Quantity 1 1 1 M4 by 18 Long BHCS M4 by 10 Long BHCS 2 Figure 9 http://www.molex.com Doc No: ATS-6381932HM Release Date: 03-23-09 Revision: B Revision Date: 10-04-10 UNCONTROLLED COPY Page 8 of 8