Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals HAND CRIMP TOOL SPECIFICATION SHEET Order No. 63819-4800 TYPE 7 FEATURES % % % % % % A full cycle ratcheting hand tool ensures complete crimps This tool is designed to be used with reeled product due to the small size of the connector This tool is designed for prototype work only and is not designed for production The reeled product must be cut into 5-inch strips to be processed in this hand tool This tool is IPC/WHMA A-620 Class 2 compliant as indicated This tool is RoHS compliant, however RoHS compliant is not required SCOPE Products: 1.20mm (.047”) Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal, 28 AWG. Terminal Terminal Order No. Series No. Reel Form Only 78172 Wire Size Insulation Diameter IPC/WHMA-A620 Terminal mm In. mm In. Strip Length AWG mm² mm In. 78172-0410 28 0.08 0.55-0.70 .022-.028 0.55-0.70 .022-.028 0.90-1.30 .035-.051 78172-0411 To achieve optimum IPC-A620 insulation crimps, use this insulation OD range. Overall insulation OD specification for terminal. Customer to cut off terminal from reel: 0.05mm (.002”) maximum Cut-off Tab. DEFINITION OF TERMS BEND UP ROLLING BRUSH BELL MOUTH 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-6381948000 Revision: A Release Date: 08-17-09 Revision Date: 08-17-09 UNCONTROLLED COPY Page 1 of 6 Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals INSULATION CRIMP FORM This crimp terminal is designed for miniaturization; therefore, each dimension of insulation crimp portion appears small as compared to the terminal material thickness. In order to avoid insulation piercing the crimp forms by the insulation barrel, coining is provided inside of the insulation barrel. For this reason, various crimp forms will occur at the tip of the insulation crimp barrel shown in the figure below. These crimp forms maybe changed completely by a small change in the wire, insulation punch, or terminal. These crimp forms are satisfactory for original function of the insulation crimp portion and it is confirmed that all of these forms below are acceptable insulation crimps. CONDITIONS: After crimping, the conductor profiles should measure the following. Terminal Series No 78172 Conductor Crimp (Ref) Insulation Crimp (Ref) Pull Force Minimum Height Width Height Width AWG mm2 mm In. mm In. mm In. mm In. N Lb. 28 0.08 0.44-0.48 .017-.019 0.85 .033 0.77 .030 0.85 .033 10.0 2.25 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. Crimping Terminals 1. Select the desired terminal listed in the preceding charts. 2. Cut a strip of the terminals approximately 5.0” off the reel. Position the terminal strip into the slot of the carrier guide with terminals facing forward. 3. Push the strip in until it locks into the (2) detent in the carrier guide and a terminal is centered with the punch nest. See Figure 1. 4. Partially close the jaws of the hand tool by squeezing the handles until you hear the fist click of the ratchet. 5. From the top of the hand tool insert the pre-stripped wire into the terminal. 6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release handles to open the jaws. Doc No: ATS-6381948000 Revision: A Release Date: 08-17-09 Revision Date: 08-17-09 UNCONTROLLED COPY Page 2 of 6 Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 7. Lift up the crimped terminal from the terminal locator. 8. Visually inspect the crimped terminal for proper crimp location. 9. If crimping more wires advance the terminal strip by (1) detent until the terminal is centered with the punch nest. 10. Repeat this procedure until all the desired terminals are crimped on the strip. WIRE LOCKS IN THE TERMINAL STRIP SLIDE TERMINAL STRIP INTO THE CARRIER GUIDE SLIDE WIRE INTO THE PUNCH NEST Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: Figure 1 CRIMP TOOL OPEN 1. Remove the plastic handles from the metal tool frame by removing the screws and 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 fine piece of equipment it needs cleaning and lubrication for a maximum service life of trouble free crimping. Light oil used at the pivot 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. 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. RATCHET RELEASE LEVER Figure 2 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 up. See Figure 2. Doc No: ATS-6381948000 Revision: A Release Date: 08-17-09 Revision Date: 08-17-09 UNCONTROLLED COPY Page 3 of 6 Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals How to Adjust Tool 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: NUMBERED ADJUSTMENT WHEEL REMOVE THE LOCKING 2MM SCREW TURN WITH A SMALL SCREW DRIVER Figure 3 TURN CLOCKWISE (CW) OR COUNTER CLOCKWISE (CCW) TO ADJUST THE PRE-LOAD 1. Remove the 2mm locking screw from the numbered adjusting wheel using a screw driver. See Figure 3. 2. Using the same screw driver turn the adjustment wheel to the next highest number. Note: The uneven numbers are in clockwise (CW) direction and the even numbers are counter clockwise (CCW). 3. Example: If the preload is set at number 5, then to increase the preload, turn the adjustment wheel until the 6th position is located over the 2mm locking screw tapped hole. If it is necessary to move to the 7th position, then the adjustment wheel should be turned counter clockwise (CCW) until the 7th position is over the 2mm locking screw tapped hole. 4. Replace the 2mm locking screw, aligning the nearest notch in the setting wheel to locking screw. 5. Check the crimp specifications and conduct a pull test after tool handle preload force is adjusted. Repeat these steps until the desired result is obtained. 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. Doc No: ATS-6381948000 Revision: A Release Date: 08-17-09 Revision Date: 08-17-09 UNCONTROLLED COPY Page 4 of 6 Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals CAUTIONS: 1. Manually powered hand tools are intended for low volume, prototyping, 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-6381948000 Revision: A Release Date: 08-17-09 Revision Date: 08-17-09 UNCONTROLLED COPY Page 5 of 6 Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminals PARTS LIST Item REF 1 2 3 4 Order No Description Quantity 63819-4800 Hand Crimp Tool Figure 4 63819-4870 Tool Kit 1 11-11-0320 Spring (Ratchet) 1 63600-0479 Spring (Main) 1 69008-0972 Adjuster Wheel 1 3 4 1 2 Figure 4 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-6381948000 Revision: A Release Date: 08-17-09 Revision Date: 08-17-09 UNCONTROLLED COPY Page 6 of 6