Tool Kit for Quick Disconnect (HRT) Female Terminal TYPE 4C Application Tooling Specification Sheet Tool Kit Order No. 63825-0770 Hand Crimp Tool Order No. 63825-0700 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, High Reliability Terminal (HRT), Female for 4.00-6.00mm² Wire. Terminal Series No. Terminal Order No. Reel Form Only 94512 94512-0300 94512-0311 94512-0301 94512-0320 94512-0310 94512-0321 Wire Size Insulation Diameter Wire Style mm² / AWG mm In. NA 4.00 NA 6.00 Strip Length mm In. 3.80-5.00 .150-.197 6.00-7.00 .236-.276 Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut-off Tab. DEFINITION OF TERMS BELL MOUTH STRIP LENGTH INSULATION CRIMP ▲SEE NOTE WIRE BRUSH SEAM CONDUCTOR CRIMP HEIGHT CUT-OFF TAB Doc No: ATS-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 TERMINAL STRIP UNCONTROLLED COPY Page 1 of 8 Tool Kit for Quick Disconnect (HRT) Female Terminal ▲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). OVERLAP FORM GEOMETRY PUNCH OVERLAP INSULATION CRIMP CONDITIONS: WIRE ANVIL After crimping, the conductor profiles should measure the following (see notes below). Terminal Series No. 94512 Wire Size AWG mm2 NA 4.0 NA 6.0 Conductor Crimp Insulation Crimp Pull Force Height Width (Ref) Height Width (Ref) Minimum mm In. mm In. mm In. mm In. N Lbs 2.45-2.60 .097-.102 3.80 .150 4.60 .181 5.05 .199 343.0 77.1 2.85-3.00 .112-.118 3.80 .150 5.15 .203 5.15 .203 392.0 88.1 Profile 4.0 X 6.0 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. 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. INSTALLATION To install the Tool Kit into the Power Crimp Head follow the steps below: 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. Locator Installation and Removal Follow the steps below to install or replace the locator. See Figure 2. Doc No: ATS-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 UNCONTROLLED COPY Page 2 of 8 Tool Kit for Quick Disconnect (HRT) Female Terminal POWER CRIMP HEAD PUNCHES M4 X 18 LONG BHCS M4 X 10 LONG BHCS LIFT UP ON THE LOCATOR PRESS DOWN ON THE BRASS PIVOT SHAFT Figure 1 ANVILS SWING LOCATOR OPEN To install the locator 1. Position the locator with the hole over the brass pivot shaft and snap it into place. Figure 2 To remove the locator 1. Open the crimp hand tool. 2. Swing the existing locator open and away from the hand tool. 3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the top of the brass pivot shaft. OPERATION LATCH LOCKED 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. LATCH UNLOCKED Figure 3 TERMINAL SWING OPEN PUSH HERE TO OPEN WIRE STOP LOCATOR LATCH IN OPEN POSITION LOCATOR Doc No: ATS-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 Figure 4 TERMINAL IN PLACE UNCONTROLLED COPY Page 3 of 8 Tool Kit for Quick Disconnect (HRT) Female Terminal Crimping Terminals 1. Select the desired terminal listed in the preceding charts. 2. Turn the Locator Lock Latch down to unlock. See Figure 3. 3. Swing the terminal locator away from the crimp tool shown in Figure 4. Some terminals with large insulation grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be loaded into the locator in the closed/crimp position. See Figure 5. TERMINAL WIRE AGAINST WIRE STOP HANDLE OPEN WIRE IN TERMINAL JAWS PARTIALLY CLOSED Figure 5 LOCATOR CLOSED PUSH HERE TO OPEN WIRE STOP Figure 6 4. Press down on the wire stop on the locator as shown in Figure 5. Insert the proper terminal into the proper nest opening. Make sure when choosing the nest opening, it will correspond with the A, or B profile on the hand tool. 5. Return the locator to its original position. 6. Turn the Locator Lock Latch up to lock. Make INSULATION CONDUCTOR PUNCH PUNCH sure that the terminal is visually centered over the punch. WIRES AGAINST 7. Insert the proper wire over the terminal. LOCATOR STOP 8. Gently touch the wire stop with the end of the wire. See Figure 6 and 7. LOCATOR 9. Compress the terminal by squeezing the tool WIRE handles until the ratchet mechanism cycle has been completed. Release handles to open the jaws. 10. 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. TERMINAL INSULATION CONDUCTOR ANVIL 11. Visually inspect the crimped terminal for proper ANVIL crimp location. Figure 7 Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 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. Doc No: ATS-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 UNCONTROLLED COPY Page 4 of 8 Tool Kit for Quick Disconnect (HRT) Female Terminal Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: LUBRICATION 1. Remove dust, moisture and other POINTS contaminants with a clean brush, or soft, (BOTH SIDES) LIGHT OIL lint-free cloth. (EVERY MONTH 2. Do not use any abrasive materials that OR Figure 8B could damage the tool. 5,000 CRIMPS) 3. Make certain all pins; pivot points and 5,000 bearing surfaces in the tool head are Figure8A protected with a thin coat of high quality machine oil. Do not oil excessively. This tool was engineered for durability, but like any fine piece of equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. The use of light oil, such as 30 weight automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life and ensure a stable calibration. See Figure 8A or 8B for lubrication points. 4. Store the tool in a clean and dry area when not in use. Miscrimps or Jams for Crimp Hand Tools Only (See 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 rotating the small slotted screw marked with an arrow. See Figure 11. Warranty This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange will not be applicable to altered, misused, or damaged tools. 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. CAUTION: Repetitive use of this tool should be avoided. 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. Doc No: ATS-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 UNCONTROLLED COPY Page 5 of 8 Tool Kit for Quick Disconnect (HRT) Female Terminal % 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. % When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and replaced. % This tool is very difficult to disassemble and reassemble. Customer repair is not recommended. The chart below shows all applications for this Tool Kit. Tool Kit Order No. Tool Tool Power Head Adapter Figure Order no. Description Order No. Description No. 63810-1050 Hand Crimp Frame (Short) N/A N/A 9 63810-1000 Hand Crimp Frame (Long) N/A N/A 9 63825-0770 63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head 10 63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head 10 Applications for the Tool Kit Hand Crimp Tool Battery Powered Tool POWER CRIMP HEAD TOOLING KIT TOOLING KIT BATTERY POWERED TOOL LOCKING PINS HAND CRIMP FRAME LONG AND SHORT Figure 9 Figure 10 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-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 UNCONTROLLED COPY Page 6 of 8 Tool Kit for Quick Disconnect (HRT) Female Terminal HAND TOOL PARTS LIST Item Number 1 2 3 4 Order Number 63810-1000 63825-0770 63825-0773 63825-0775 Description Hand Crimp Frame (Long) Tool Kit with Locator Locator Base Locator (only) M4 X 8mm LONG BHCS Quantity 1 1 1 REF 1 3 RATCHET RELEASE SCREW 2 WITH TOOL KIT 4 LOCATOR ONLY M4 X 10mm LONG BHCS M4 X 18mm LONG BHCS Figure 11 2 Doc No: ATS-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 UNCONTROLLED COPY Page 7 of 8 Tool Kit for Quick Disconnect (HRT) Female Terminal POWER HEAD PARTS LIST Item 1 2 Order No 63816-0300 63823-1770 Engineering No. 63816-0300 63823-1770 Description Power Crimp Head Tool Kit Quantity 1 1 2 1 1 M4 by 8 Long BHCS M4 by 18 Long BHCS M4 by 10 Long BHCS 2 Figure 12 http://www.molex.com Doc No: ATS-6382507HM Release Date: 04-04-11 Revision: A Revision Date: 04-04-11 UNCONTROLLED COPY Page 8 of 8