Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals HAND CRIMP TOOL Specification Sheet Order No. 63823-5600 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 IPC/WHMA A-620 Class 2 compliant This tool is RoHS compliant, however RoHS compliant is not required SCOPE Products: 2.00mm (.079") Pitch Male Crimp Terminals, 14 - 18 AWG. Terminal Series No. 50638 Terminal Order No. Wire Size and Type Insulation Diameter (Maximum Strip Length Loose Reel AWG mm² mm In. mm In. 50638-9128 50638-9028 14 - 18 2.21- 0.81 3.80 .150 3.90 – 4.40 .154-.173 50638-9149 50638-9049 DEFINITION OF TERMS BEND UP BRUSH BELL MOUTH ROLLING CONDUCTOR CRIMP INSULATION CRIMP 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-638235600 Revision: A Release Date: 03-08-10 Revision Date: 03-08-10 UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals Fig3 CONDITIONS: After crimping, the conductor profiles should measure the following. Terminal Series No. 50638 Conductor Crimp Insulation Crimp Pull Force Profile Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Minimum AWG mm2 mm In. mm In. mm In. mm In. N Lb. 16 18 14 14 2.21 1.59 - 1.69 .063-.067 2.60 .102 4.00 .157 4.00 .157 147.0 33.0 X 16 1.31 1.39 - 1.49 .055-.059 2.60 .102 3.90 .154 4.00 .157 127.0 28.5 X 18 0.81 1.22 - 1.32 .048-.052 2.60 .102 3.70 .146 4.00 .157 88.2 19.8 X 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. LOCATOR IN DOWN POSTION HANDLE WILL SPRING OPEN Crimping Terminals 1. Select the desired terminal listed in the preceding charts. 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. SQUEEZE HANDLES 3. While holding the locator button in, load TOGETHER the terminal into the proper nest opening Figure 1 in the locator based on the wire gauge or terminal type markings on the hand tooling. See Figure 3. LOCATOR PUSHED THRU TOOLING Figure 2 PUSH ON THE LOCATOR BUTTON RELEASE LOCATOR BUTTON LOCATOR LOCATOR BUTTON PUSHED IN Figure 3 TERMINAL TERMINAL Doc No: ATS-638235600 Revision: A Release Date: 03-08-10 Revision Date: 03-08-10 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals 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. TOOLING PARTIALLY CLOSED PARTIALLY CLOSE HANDLE OPEN POSITION FIRST RATCHET POSITION Figure 4 WIRE AGAINST THE WIRE STOP TERMINAL WIRE STOP IS PART OF THE LOCATOR WIRE TERMINAL Figure 5 PRE-STRIPPED WIRE 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-638235600 Revision: A Release Date: 03-08-10 Revision Date: 03-08-10 UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool for 2.00mm (.079") Pitch Male 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 performed to check hand tool crimp. Pull Force value Must exceed the Minimum pull force specifications listed. LOCATOR Locator Replacement 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. SQUEEZE HERE SQUEEZE HERE MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION Figure 7A 1. Open the crimp hand tool. TOP SLOTS OF 2. Squeeze gently on the lower area shown in HANDTOOL Figure 7A with your thumb and index finger. TOP HOOKS 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. Figure 7B 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 LOWER TABS shown in Figure 7B. 6. Holding onto the lower part of the locator with your thumb and index finger, insert the locators 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. JAWS OPEN 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 if using the left handed application along with the locator. Follow the steps below: PULL OPEN TOOLING TOOLING M3 BHCS 1. The locator must be removed before reversing the tooling. Figure 8 2. Remove the M3 BHCS which is holding the upper tooling. PUSH ON 3. Flip the upper tooling to the opposite side and HANDLE replace the M3 BHCS. Make 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. Doc No: ATS-638235600 Revision: A Release Date: 03-08-10 Revision Date: 03-08-10 UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals MATCH UP MARKS 4. Do the same thing with the lower tooling and tighten the M3 screws. Be sure the small markings line up. 5. Reinstall the locator by following the Instructions in the locator replacement section. Figure 9 Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: FRONT BACK 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. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) Figure 10 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. RATCHET RELEASE LEVER 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 10. Using the index finger squeeze the link towards the top of the hand tool frame. This will release the preload adjustment wheel. Doc No: ATS-638235600 Revision: A Release Date: 03-08-10 Revision Date: 03-08-10 UNCONTROLLED COPY Figure 11 Page 5 of 7 Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals 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 SQUEEZE HOLD THE HAND conduct a pull test after tool handle THE LINK IN RATCHET TOOL IN POSITION THE HANDLE preload force is adjusted. RELEASE LEVER 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 SETTING repair or exchange will not be applicable WHEEL 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. Figure 12 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-638235600 Revision: A Release Date: 03-08-10 Revision Date: 03-08-10 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for 2.00mm (.079") Pitch Male Crimp Terminals PARTS LIST Item Number REF 1 2 3 Order Number 63823-5600 63823-5675 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 2 1 3 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] 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-638235600 Revision: A Release Date: 03-08-10 Revision Date: 03-08-10 UNCONTROLLED COPY Page 7 of 7