MOLEX 0638234975

Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
HAND CRIMP TOOL
Specification Sheet
Order No. 63823-4900
TYPE 4D
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: 2.00mm (.079") Pitch Micro Blade Board -In Crimp Terminal 26-30 AWG.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
50034-8100 50034-8000 26-30 0.12-0.05 0.80-1.40 .031-.055 1.40-1.90 .055-.075
Customer to cut off terminal from reel: 0,.2mm (.008”) maximum Cut-off Tab.
Terminal Series No.
50034
DEFINITION OF TERMS
BRUSH
BEND UP
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
CRIMP
ROLLING
TWISTING
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Doc No: ATS-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 1 of 8
Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal Series No
50034
Terminal Series No
50034
Conductor Crimp
Profile
Height (Ref.)
Width (Ref.)
AWG mm2
mm
In.
mm
In. 26 28 30
26 0.12 0.57-0.62 .022-.024 1.05 .041 X
28 0.08 0.56-0.61 .022-.024 1.05 .041
X
30 0.05 0.53-0.58 .021-.023 1.05 .041
X
Wire Size
Insulation Crimp
Pull Force
Max Height (Ref.) Width (Ref.) Minimum
AWG mm2
mm
In.
mm
In.
N Lb.
26 0.12
1.15
.045
1.41 .056 19.6 4.4
28 0.08
1.15
.045
1.41 .056 9.8 2.2
30 0.05
1.10
.043
1.41 .056 4.9 1.1
Wire Size
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.
Crimping Terminals
1. Select the desired terminal listed
from the preceding charts. Then
install it in the proper locator (See
chart above and see Locator
Installation on page 5).
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.
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOGETHER
Figure 2
PUSH ON THE
LOCATOR BUTTON
Figure 1
Doc No: ATS-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 2 of 8
Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
LOCATOR
PUSHED THRU
TOOLING
RELEASE
LOCATOR BUTTON
LOCATOR
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Figure 3
TERMINAL
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 bee n completed. Release the handles to open
the jaws.
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 4
TERMINAL
WIRE AGAINST THE
WIRE STOP
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.
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.
Doc No: ATS-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 3 of 8
Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
WIRE
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.
WIRE STOP
Figure 6
Locator Replacement
TERMINAL
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.
LOCATOR
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
TOP SLOTS OF
HANDTOOL
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
TOP HOOKS
Figure 8
Figure 7B
PUSH ON
HANDLE
LOWER TABS
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 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-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 4 of 8
Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
Right or Left Hand Operation
MATCH
UP MARKS
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.
2. Remove the M3 BHCS which is
holding the upper tooling.
Figure 9
FRONT
BACK
RATCHET RELEASE
LEVER
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 LUBRICATION POINTS
are on the outside of the hand
(BOTH SIDES) LIGHT OIL
tool frame. See Figure 8 and 9.
(EVERY 3 MONTHS OR
5,000 CRIMPS)
4. Do the same thing with the lower
tooling and tighten the M3
screws. Be sure the small
Figure 10
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:
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
Figure 11
HOLD THE HAND
TOOL IN POSITION
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.
Figure 12
3. Make certain all pins; pivot points and
bearing surfaces are protected with a
SETTING
thin coat of high quality machine oil.
WHEEL
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.
Doc No: ATS-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 5 of 8
Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
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 11
How to Adjust Tool Preload
(See Figure 12)
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 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 counter-clockwise (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.
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.
Doc No: ATS-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 6 of 8
Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
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-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 7 of 8
Hand Crimp Tool for 2.00mm (.079") Pitch Micro Blade Board-In Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63823-4900
63823-4975
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly (Red)
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
[email protected]
Far East North Headquarters
Yamato, Kanagawa, Japan
81-462-65-2324
[email protected]
3
Far East South Headquarters
Jurong, Singapore
65-6-268-6868
[email protected]
European Headquarters
Munich, Germany
49-89-413092-0
[email protected]
Corporate Headquarters
2222 Wellington Ct.
Lisle, IL 60532 U.S.A.
630-969-4550
Fax: 630-969-1352
Visit our Web site at http://www.molex.com
Doc No: ATS-638234900
Revision: A
Release Date: 04-09-10
Revision Date: 04-09-10
UNCONTROLLED COPY
Page 8 of 8