Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals Hand Crimp Tool Application Tooling Specification Sheet TYPE 4D Order No. 63819-0800 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 Dies and Locator from this tool can be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V), with the use of the 63816-0800 Crimp Head Many different tool kits can be used with a single Battery Powered Crimp Tool This tool is RoHS compliant, however RoHS compliant is not required SCOPE Products: 1.57mm (.062") Diameter, Standard .062" Pin and Socket Crimp Terminals, 24-30 AWG 2.50mm (.098") Pitch SPOXTM Wire-to-Wire Male Crimp Terminals, 22-28 AWG 2.54mm (.100) KK(R) High Pressure Crimp Terminals, 22-30 AWG 2.50mm (.098") Pitch Wire-to-Wire Male Crimp Terminal, 22-28 AWG. Terminal Series No. 1854 1855 5241 7879 35053 Terminal Order No. Wire Size Insulation Diameter Loose Piece (1) Reel AWG mm mm In. 02-06-2132 02-06-6144 02-06-2131 02-06-6143 02-06-6135 04-01-0811 02-06-6130 04-01-0809 24-30 0.20-0.05 1.02-1.78 .040-.070 02-06-6136 39-00-0335 02-06-6137 39-00-0280 02-06-6139 39-00-0337 02-06-6138 39-00-0336 02-06-1132 02-06-5148 02-06-1131 02-06-5147 02-06-1143 04-01-0812 02-06-1141 04-01-0810 24-30 0.20-0.05 1.02-1.78 .040-.070 02-06-5135 39-00-0339 02-06-5130 39-00-0338 02-06-5139 39-00-0341 02-06-5138 39-00-0340 08-70-0103 08-70-0102 22-28 0.35-0.08 1.15-1.90 .045-.075 08-50-0005 50-29-1745 08-50-0004 50-29-1635 08-55-0127 46999-0101 08-55-0124 50-29-1744 22-30 0.35-0.05 1.02-1.57 .040-.062 08-55-0129 08-55-0128 50-29-1900 35053-9002 22-28 0.35-0.08 1.15-1.90 .045-.075 (1) Customer to cut off terminal from reel: 0.13mm (.005") maximum Cut-off Tab. Doc No: ATS-638190800 Revision: D Release Date: 10-25-07 Revision Date: 09-16-15 UNCONTROLLED COPY Strip Length mm In. 3.17-3.96 .125-.156 3.17-3.96 .125-.156 2.60-3.20 .102-.126 2.54-3.17 .100-.125 2.30-2.90 .091-.114 Page 1 of 8 Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals BEND UP DEFINITION OF TERMS BRUSH BELL MOUTH INSULATION CRIMP SEE NOTE CONDUCTOR 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. 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). PUNCH OVERLAP FORM GEOMETRY OVERLAP INSULATION CRIMP CONDITIONS: After crimping, the conductor profiles should measure the following. See Notes below. Terminal Series No 1854 1855 5241 7879 35053 Doc No: ATS-638190800 Revision: D Wire Size AWG mm2 24 0.20 26 0.12 28 0.08 30 0.05 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 22 0.35 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 ANVIL WIRE Conductor Crimp Insulation Crimp Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) mm In. mm In. mm In. mm In. 0.69-0.79 .027-.031 1.41 .055 1.42 .056 1.63 .064 0.65-0.75 .025-.029 1.37 .053 1.38 .054 1.41 .055 0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055 0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055 0.69-0.79 .027-.031 1.41 .055 1.42 .056 1.63 .064 0.65-0.75 .025-.029 1.37 .053 1.38 .054 1.41 .055 0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055 0.65-0.75 .025-.029 1.37 .053 1.34 .053 1.41 .055 0.72-0.82 .028-.032 1.43 .056 1.46 .058 1.63 .064 0.72-0.82 .028-.032 1.43 .056 1.44 .057 1.63 .064 0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055 0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055 0.70-0.80 .028-.031 1.41 .055 1.42 .056 1.63 .064 0.70-0.80 .028-.031 1.41 .055 1.42 .056 1.63 .064 0.65-0.75 .025-.029 1.37 .053 1.37 .053 1.41 .055 0.65-0.75 .025-.029 1.37 .053 1.37 .053 1.41 .055 0.65-0.75 .025-.029 1.37 .053 1.37 .053 1.41 .055 0.72-0.82 .028-.032 1.43 .056 1.46 .058 1.63 .064 0.72-0.82 .028-.032 1.43 .056 1.44 .057 1.63 .064 0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055 0.69-0.79 .027-.031 1.38 .054 1.41 .055 1.41 .055 Release Date: 10-25-07 Revision Date: 09-16-15 UNCONTROLLED COPY Page 2 of 8 Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals Terminal Series No 1854 1855 5241 7879 35053 Wire Size AWG mm2 24 0.20 26 0.12 28 0.08 30 0.05 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 22 0.35 24 0.20 26 0.12 28 0.08 30 0.05 22 0.35 24 0.20 26 0.12 28 0.08 Profile Locator Pull Force Minimum A B C D Order No. Color N Lb. 26-30 22-24 22-24 26-30 28.9 6.50 X 17.8 4.00 X 63819-0875 Red 11.1 2.50 X 6.7 1.50 X 28.9 6.50 X 17.8 4.00 X 63819-0875 Red 11.1 2.50 X 6.7 1.50 X 39.2 8.80 X 29.4 6.60 X 63819-0875 Red 19.6 4.40 X 9.8 2.20 X 44.8 10.00 X 28.9 6.50 X 17.8 4.00 X 63819-0875 Red 11.1 2.50 X 6.7 1.50 X 39.2 8.80 X 29.4 6.60 X 63819-0876 Yellow 19.6 4.40 X 9.8 2.20 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 document 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 LOCATOR HANDLE WILL IN DOWN SPRING OPEN Minimum pull force specifications listed. POSTION OPERATION CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as damage can occur to the tool frame and/or crimp dies. SQUEEZE HANDLES TOGETHER 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. Doc No: ATS-638190800 Revision: D Release Date: 10-25-07 Revision Date: 09-16-15 Figure 2 PUSH ON THE LOCATOR BUTTON Figure 1 UNCONTROLLED COPY Page 3 of 8 Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals Crimping Terminals 1. Select the desired terminal listed in the preceding charts and install the proper locator. See chart above and locator replacement 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. 3. While holding the locator button in, 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. LOCATOR PUSHED THRU TOOLING RELEASE LOCATOR BUTTON LOCATOR LOCATOR BUTTON PUSHED IN TERMINAL 4. 5. 6. 7. Figure 3 TERMINAL Release the locator button, allowing the locator to return to the crimping position. Close the tool handle until the first ratchet position engages. See Figure 4. Insert the properly stripped wire through the terminal and against the wire stop. See Figure 5. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release the handles to open the jaws. 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. Doc No: ATS-638190800 Revision: D Release Date: 10-25-07 Revision Date: 09-16-15 UNCONTROLLED COPY Page 4 of 8 Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals 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 TERMINAL Locator Replacement Figure 6 LOCATOR 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. 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 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. 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: 1. The locator must be removed before reversing the tooling. Doc No: ATS-638190800 Revision: D Release Date: 10-25-07 Revision Date: 09-16-15 SQUEEZE HERE SQUEEZE HERE Figure 7A TOP SLOTS OF HANDTOOL MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION TOP HOOKS Figure 7B LOWER TABS JAWS OPEN TOOLING PULL OPEN TOOLING M3 BHCS Figure 8 PUSH ON HANDLE UNCONTROLLED COPY Page 5 of 8 Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals 2. Remove the M3 BHCS which is holding the upper MATCH tooling. UP MARKS 3. Flip the upper tooling to the opposite side and replace the M3 BHCS. Make sure the small markings on the Figure 9 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. 4. Do the same thing with the lower tooling and tighten FRONT the M3 screws. Be sure the small markings line up. 5. Reinstall the locator by following the Instructions in the locator replacement section. BACK 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 LUBRICATION POINTS thin coat of high quality machine oil. Do not oil excessively. The tool was (BOTH SIDES) LIGHT OIL engineered for durability but like any other equipment it needs cleaning and (EVERY 3 MONTHS OR 5,000 CRIMPS) 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. Figure 10 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. RATCHET RELEASE LEVER 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: Figure 11 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. Doc No: ATS-638190800 Revision: D Release Date: 10-25-07 Revision Date: 09-16-15 UNCONTROLLED COPY Page 6 of 8 Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals 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. RATCHET RELEASE LEVER SQUEEZE THE LINK IN THE HANDLE HOLD THE HAND TOOL IN POSITION Figure 12 SETTING WHEEL 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. 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-638190800 Revision: D Release Date: 10-25-07 Revision Date: 09-16-15 UNCONTROLLED COPY Page 7 of 8 Hand Crimp Tool For .062" Pin and Socket, SPOXTM and KK(R) High Pressure Crimp Terminals PARTS LIST Item Number REF 1 1 2 3 Order Number 63819-0800 63819-0875 63819-0876 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly (Red) Locator Assembly (Yellow) Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 1 2 1 RATCHET RELEASE LEVER Figure 13 3 Visit our Web site at http://www.molex.com Doc No: ATS-638190800 Revision: D Release Date: 10-25-07 Revision Date: 09-16-15 UNCONTROLLED COPY Page 8 of 8