Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals Modular Crimp Head Order No. 63819-6870 Application Tooling Specification Sheet TYPE 4A Hand Crimp Tool Order No. 63819-6800 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 Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100, accompanied by Air Powered Crimp Adapter (Order No. 63816-0700). Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V) accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600). SCOPE Products: VersaBlade™ Industry standard .070" tab terminals, 20 – 22 AWG Terminal Series No. 35745 35746 35747 35748 Insulation Diameter Terminal IPC/WHMA-A620 Maximum AWG mm² mm In. mm In. 35745-0110 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 35746-0110 35746-0111 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 35747-0110 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 35748-0110 35748-0111 20-22 0.50-0.35 2.36-2.60 .093-.102 2.60 .102 To achieve optimum IPC-A620 insulation crimps, use this insulation OD range. Overall insulation OD specification for terminal. Terminal Order No. Wire Size DEFINITION OF TERMS BELL MOUTH BRUSH Strip Length mm 4.00-4.80 4.00-4.80 4.00-4.80 4.00-4.80 In. .157-.189 .157-.189 .157-.189 .157-.189 BEND UP SEAM INSULATION CRIMP RO TWISTING STRIP LENGTH BEND DOWN CUT-OFF TAB CONDUCTOR COND.CRIMP CRIMP HEIGHT This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope. Doc No: ATS-6381968HM Revision: A Release Date: 7-23-10 Revision Date: 7-23-10 UNCONTROLLED COPY Page 1 of 5 Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals CONDITIONS: After crimping, the crimp profiles should measure the following (see notes on page 3). Terminal Series No 35745 35746 35747 35748 Wire Size AWG 20 22 20 22 20 22 20 22 mm2 0.50 0.35 0.50 0.35 0.50 0.35 0.50 0.35 Conductor Crimp (Ref.) Height Width mm In. mm In. 1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 1.25 - 1.35 ..049 - .053 1.70 - 1.90 .067 - .075 1.15 - 1.25 .045 - .049 1.70 - 1.90 .067 - .075 Insulation Crimp (Ref.) Height Width mm In. mm In. 2.45 ..096 2.90 - 3.10 .114 - .122 2.25 .089 2.90 - 3.10 .114 - .122 2.45 ..096 2.90 - 3.10 .114 - .122 2.25 .089 2.90 - 3.10 .114 - .122 2.45 ..096 2.90 - 3.10 .114 - .122 2.25 .089 2.90 - 3.10 .114 - .122 2.45 ..096 2.90 - 3.10 .114 - .122 2.25 .089 2.90 - 3.10 .114 - .122 Pull Force Minimum N Lb. 58.7 13.2 39.1 8.8 58.7 13.2 39.1 8.8 58.7 13.2 39.1 8.8 58.7 13.2 39.1 8.8 Profile 20 22 X X X X X X X X Pull Force should be measured with no influence from the insulation crimp. The above specifications are guidelines to an optimum crimp. OPERATION 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. Crimping Terminals 1. Place the terminal into the correct die profile until the terminal stopped by the locator. 2. Bring the wire stop blade down; make sure the wire stop located behind the conductor grip. 3. Place a pre-striped wire into the terminal until the end of wire touching the wire stop. See Figure 2. 4. Close the tool until the ratchet releases, the tool handles will then spring open. 5. Carefully remove the crimped terminal. WIRE STOP BLADE TERMINAL INSULATION PUNCH CONDUCTOR PUNCH WIRE STOP BLADE INSULATION PUNCH LOCATOR WIRE TERMINAL WIRE Figure 1 CONDUCTOR ANVIL Figure 2 INSULATION ANVIL Note: The tamper proof ratchet action will not release the tool until it has been fully closed. Doc No: ATS-6381968HM Revision: A Release Date: 7-23-10 Revision Date: 7-23-10 UNCONTROLLED COPY Page 2 of 5 Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals 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 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. 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 lifting the ratchet release lever. See Figure 6. 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: Repetitive use of this tool should be avoided. 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. Notes: 1. This tool should only be used for the terminals and wire gauges specified on this sheet. 2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above). Variations in tools, terminals, wire stranding and insulation types may affect crimp height. 3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all insulation sizes. 4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased. Doc No: ATS-6381968HM Revision: A Release Date: 7-23-10 Revision Date: 7-23-10 UNCONTROLLED COPY Page 3 of 5 Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals 5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp testing. 6. Molex does not certify crimp hand tools. CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. Applications for the Modular Crimp Head WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See Chart below for the correct Manual or Specification Sheet. WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the power by unplugging or turn off the Actuator from its power source. 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. The chart below shows all applications for this Modular Crimp Head. Modular Crimp Head Order No. 63819-6870 Tool Tool Adapter Adapter Figure Order no. Description Order No. Description No. 63816-0000 Hand Crimp Frame (Short) N/A N/A 3 63816-0050 Hand Crimp Frame (Long) N/A N/A 3 63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 4 63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 4 Air Power Tool 63816-0700 Air Power Crimp Adapter 5 63816-0100 Applications for the Modular Crimp Head Hand Crimp Tool Battery Powered Tool MODULAR CRIMP HEAD LOCKING PINS MODULAR CRIMP HEAD LOCKING PINS Air Powered Tool LOCKING PINS MODULAR CRIMP HEAD AIR POWER CRIMP ADAPTER BATTERY POWER B E LOCKING PINS HAND CRIMP FRAME LONG OR SHORT Figure 3 Doc No: ATS-6381968HM Revision: A BATTERY POWERED TOOL Figure 4 Release Date: 7-23-10 Revision Date: 7-23-10 LOCKING PINS AIR POWER TOOL UNCONTROLLED COPY Figure 5 Page 4 of 5 Hand Crimp Tool for VersaBlade™ Industry standard .070" Terminals PARTS LIST Hand Crimp Tool 63819-6800 Item Order Number Description Quantity 1 63819-6870 Modular Crimp Head 1 (Ref) 2 63816-0050 Hand Crimp Frame (long) 1 (Ref) 3 63819-6875 Locator 1 4 63816-0001 Locking Pin 2 5 63600-0525 Handle Spring 1 6 63600-0520 Crimping Spring 2 5 HANDLE SPRING 2 M4 X 14mm LONG BHCS RATCHET RELEASE LEVER 3 4 1 6 CRIMPING SPRING (2) Figure 6 http://www.molex.com Doc No: ATS-6381968HM Revision: A Release Date: 7-23-10 Revision Date: 7-23-10 UNCONTROLLED COPY Page 5 of 5