Transcription

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp TerminalsHAND CRIMPTOOLApplication ToolingSpecification SheetTYPE 4DOrder No. 63819-1100FEATURESA full cycle ratcheting hand tool ensures complete crimpsErgonomic soft grip handles for comfortable crimpingA precision user-friendly terminal locator wire stop holds terminals in the proper crimping positionRight and Left handed applicationsThis tool is WHMA-IPCA620 Class 2 compliant as indicatedThis tool is RoHS compliant, however RoHS compliant is not requiredSCOPEProducts: 2.36mm (.093") Diameter, Standard .093" Pin and Socket Crimp Terminals, 14-20 AWG,3.18mm (.125") Diameter, Standard .125" Pin and Socket Crimp Terminals, 16-18 AWG,and Commoning Terminals, 14-16 AWG.TerminalSeries l Order No.Wire SizeInsulation DiameterStrip LengthLoose PieceAWGmm²mmIn.mmIn. Reel02-09-1103 39-00-028802-09-1104 39-00-028902-09-5106 39-00-029414-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.15002-09-5111 39-00-029539-00-007202-09-2103 39-00-029702-09-6106 39-00-029914-20 2.08-0.52 1.65-4.06 .065-.160 3.30-3.80 .130-.15002-09-611005-02-005005-02-0049 14-16 2.08-1.31 3.56 Max. .140 Max. 3.30-3.80 .130-.15002-09-810914-18 2.08-0.82 4.06 Max. .160 Max. 3.30-3.80 .130-.15018-12-222216-18 1.31-0.82 3.05 Max. .120 Max. 3.30-3.80 .130-.15018-12-122216-18 1.31-0.82 3.05 Max. .120 Max. 3.30-3.80 .130-.15002-09-216714-20 2.08-0.52 3.56 Max. .140 Max. 3.30-3.80 .130-.15002-09-1206 02-09-517014-20 2.08-0.52 3.56 Max. .140 Max. 3.30-3.80 .130-.15002-09-111214-18 2.08-0.82 3.56 Max. .140 Max. 3.60-4.10 .140-.160 Customer to cut off terminal from reel: 0.18mm (.007”) maximum Cut-off Tab.See Conditions on page 3.Doc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYPage 1 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp TerminalsDEFINITION OF TERMSBEND UPCONDUCTORCRIMPINSULATION CRIMP SEE NOTEBRUSHBELL MOUTHROLLINGTWISTINGSTRIPLENGTHBENDDOWNCRIMP HEIGHTThe above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in thescope.OVERLAP FORM GEOMETRY Insulation Crimp Note:Due to the terminal’s insulation grip designand/or insulation diameter range, this tooluses “overlap” form geometry in theinsulation punch. This produces an overlapinsulation crimp (A620 – compliant). Whilethe insulation punch profile may appear“lopsided”, this is a normal condition for thistool. See figure to the right. (Some tools withmultiple crimp pockets may not have the“overlap” profile on all ILWIREAfter crimping, the conductor profiles should measure the following.Terminal Series No118911901457-21973-22046Doc No: ATS-638191100Revision: BWire SizeAWG mm214 2.0816 1.3118 0.8220 0.5214 2.0816 1.3118 0.8220 0.5214 2.0816 1.3114 2.0816 1.3118 0.8216 1.3118 0.82Conductor CrimpInsulation CrimpHeight (Ref.)Width (Ref.) Height (Ref.) Width (Ref.)1.62 - 1.72 .064-.068 2.36 .093 3.25 .128 3.50 .1381.46 – 1.56 .057-.061 2.36 .093 3.09 .122 3.43 .1351.35 – 1.45 .053-.057 2.08 .082 2.74 .108 3.09 .1221.30 – 1.40 .051-.055 2.08 .082 2.65 .104 3.02 .1191.62 - 1.72 .064-.068 2.36 .093 3.25 .128 3.50 .1381.46 – 1.56 .057-.061 2.36 .093 3.09 .122 3.43 .1351.35 – 1.45 .053-.057 2.08 .082 2.74 .108 3.09 .1221.30 – 1.40 .051-.055 2.08 .082 2.65 .104 3.02 .1191.62 - 1.72 .064-.068 2.40 .094 3.25 .128 3.53 .1391.52 – 1.62 .060-.064 2.35 .093 3.16 .124 3.48 .1371.62 – 1.72 .064-.068 2.39 .094 3.23 .127 3.50 .1381.52 – 1.62 .060-.064 2.35 .093 3.15 .124 3.44 .1351.37 – 1.47 .054-.058 2.09 .082 2.76 .109 3.07 .1211.65 – 1.75 .065-.069 2.38 .094 3.30 .130 3.55 .1401.57 – 1.67 .062-.066 2.34 .092 3.19 .126 3.47 .137Release Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYPage 2 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp TerminalsTerminal Series No2047454945507238Wire SizeAWG mm216 1.3118 0.8214 2.0816 1.3118 0.8220 0.5214 2.0816 1.3118 0.8220 0.5214 2.0816 1.3118 0.82Conductor CrimpInsulation CrimpHeight (Ref.)Width (Ref.) Height (Ref.) Width (Ref.)1.65 – 1.75 .065-.069 2.38 .094 3.30 .130 3.55 .1401.57 – 1.67 .062-.066 2.34 .092 3.19 .126 3.47 .1371.57 - 1.67 .062-.066 2.39 .094 3.20 .126 3.49 .1371.46 – 1.56 .057-.061 2.35 .093 3.10 .122 3.46 .1361.33 – 1.43 .052-.056 2.08 .082 2.72 .107 3.08 .1211.25 – 1.35 .049-.053 2.07 .081 2.65 .104 3.00 .1181.57 - 1.67 .062-.066 2.39 .094 3.20 .126 3.49 .1371.46 – 1.56 .057-.061 2.35 .093 3.10 .122 3.46 .1361.33 – 1.43 .052-.056 2.08 .082 2.72 .107 3.08 .1211.25 – 1.35 .049-.053 2.07 .081 2.65 .104 3.00 .1181.69 – 1.79 .067-.070 2.40 .094 3.24 .128 3.51 .1381.65 – 1.75 .065-.069 2.38 .094 3.24 .128 3.51 .1381.59 – 1.69 .063-.067 2.37 .093 3.18 .125 3.46 .136Wire SizePull Force MinimumProfileLocatorAWG mm2NLb.ABOrder 3819-1176 31155.035.00X63819-1176 1177 77 325.00XTo Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter rangesare recommended:1. Profile A: 3.00mm - 2.20mm (.118 - 087 inch)2. Profile B: 2.85mm -2.00mm (.112 - .079 inch)Terminal Series NoTool 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.Doc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYPage 3 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp TerminalsNote:A crimp height chart is provided with this manual as Reference Only. Due to thewide range of wires, strands, insulation diameters, and durometers available, actualcrimp height measurements may very slightly. An occasional, destructive, pull forcetest should be preformed to check hand tool crimp. Pull Force value Must exceedthe Minimum pull force specifications listed.HANDLE WILLSPRING OPENOPERATIONCAUTION: Install only Molex terminals listed above with this tool. Do not crimphardened objects as damage can occur to the tool or die.SQUEEZEHANDLESTOGETHEROpen 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.Figure 1Crimping Terminals1. Select the desired terminal listed from the preceding charts and install the proper locator (See chart above andsee Locator Installation on page 5).2. Make sure the center of the locator is in the down position. With the locator attached, push the locator buttonon the back of the hand tool to bring the locator forward through the tooling. See Figure 2.RELEASELOCATORBUTTONLOCATOR INDOWN POSTIONTERMINALLOCATORPUSHED THRUTOOLINGLOCATORBUTTONPUSHED INFigure 2PUSH ON THELOCATOR BUTTONTERMINALFigure 33. While holding in the locator button, load the terminal into the propernest opening in the locator, based on the wire gauge or terminal typemarkings on the hand tooling. See Figure 3.4. Release the locator button, allowing the locator to return to the crimpingposition.5. Close the tool handle until the first ratchet position engages. SeeFigure 4.6. Insert the properly stripped wire through the terminal and against thewire stop. See Figure 5.7. Crimp the terminal by squeezing the tool handles until the ratchetmechanism cycle has been completed. Release the handles to openthe jaws.Doc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12TOOLINGPARTIALLYCLOSEDPARTIALLYCLOSE HANDLEOPENPOSITIONFIRST RATCHETPOSITIONUNCONTROLLED COPYFigure 4Page 4 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp TerminalsWIRE STOP ISPART OF THELOCATORWIRE AGAINSTTHE WIRESTOPTERMINALPRE-STRIPPEDWIREFigure 5TERMINALWIRENote: The tamper proof ratchet action will not release the tool until it has been fully closed.8. Remove the crimped terminal from the terminallocator by pulling on the wire.9. Visually inspect the crimped terminal for propercrimp location.10. On some large O.D. wires, it may not be possible toinsert the wire with the tool partially closed. Thosewires should be inserted with the hand tool in theopen position. Insert the wire above the terminal inthe punch and against the wire stop then close thetool. See Figure 6.WIREWIRE STOPFigure 6Locator InstallationTERMINALSee the parts list on the last page of this document for the proper locator order number. Follow the steps below toreplace the locator.LOCATORSQUEEZEHEREJAWS OPENMAKE SURECENTER OF LOCATORIS IN THEDOWN POSITIONTOP SLOTS OFHANDTOOLSQUEEZEHEREPULL OPENTOOLINGTOOLINGM3 BHCSTOP HOOKSFigure 8Figure 7BPUSH ONHANDLEFigure 7ALOWER TABSDoc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYPage 5 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals1. 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 thelocator 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 Figure7A.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 yourthumb and index finger, insert the locator top hooksMATCH(2) into the hand tool top slots.UP MARKS7. Rotate the locator down and press the lower tabsinto the two bottom slots of the hand tool. Tosecure the locator into place, the lower tabs mustsnap into place on the hand tool frame.Figure 9Right or Left Hand OperationBACKFRONTThis hand tool has an added feature that can be converted from a right handed application to a left handedapplication. It is necessary to reverse the tooling along with the locator if using the left handed application. Followthe steps below:1. The locator must be removed before reversing the tooling.2. Remove the M3 BHCS which is holding the upper tooling.3. Flip the upper tooling to the opposite side and replace the M3 BHCS Makesure the small markings on the front and back of the hand tool frame matchup 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 the M3 screws. Be surethe small markings line up.5. Reinstall the locator by following the Instructions in the locator replacementsection.MaintenanceLUBRICATION POINTS(BOTH SIDES) LIGHT OIL(EVERY 3 MONTHS OR5,000 CRIMPS)It is recommended that each operator of the tool be made aware of, andresponsible 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 witha thin coat of high quality machine oil. Do not oil excessively. The toolwas engineered for durability but like any other equipment it needscleaning and lubrication for a maximum service life of trouble free crimping.Light oil (such as 30 weight automotive oil) used at the oil points, every5,000 crimps or 3 months, will significantly enhance the tool life.4. Wipe excess oil from hand tool, particularly from crimping area. Oiltransferred from the crimping area onto certain terminations may affect theelectrical characteristics of an application.Doc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYFigure 10RATCHET RELEASELEVERFigure 11Page 6 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp Terminals5. 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 JamsShould this tool ever become stuck orjammed in a partially closed position, DoNot force the handles open or closed.The tool will open easily by pressing up onthe ratchet release lever in the movablehandle. See Figure 11RATCHETRELEASE LEVERSQUEEZETHE LINK INTHE HANDLEHOLD THE HANDTOOL IN POSITIONHow to Adjust Tool Preload(See Figure 10)This hand tool is factory preset to 25-45LBS. preload. It may be necessary overSETTINGthe life of the tool to adjust tool handleWHEELpreload force. Listed below are the stepsrequired to adjust the crimping force of the hand tool to obtain proper crimp conditions:Figure 121. Hold the hand tool in the palm of your hand as shown in Figure 12. Using the index finger squeeze the linktowards 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.WarrantyThis tool is for electrical terminal crimping purposes only. This tool is made of the best quality materials. All vitalcomponents are long life tested. All tools are warranted to be free of manufacturing defects for a period of 30days. Should such a defect occur, we will repair or exchange the tool free of charge. This repair or exchange willnot 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.CAUTIONS:1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended forproduction 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.Doc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYPage 7 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp TerminalsCertificationMolex does not certify or re-certify hand tools but rather supplies the following guidelines for customers to re-certifyhand tools.%This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pulltesting.% If the tool does not meet minimum pull force values, handle preload should be increased and the pull testrerun, (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 andreplaced.Doc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYPage 8 of 9

Hand Crimp Tool For .093” and .125” Pin and Socket and Commoning Crimp TerminalsPARTS LISTItem NumberREF11123Order 0-010463810-0105DescriptionHand Crimp ToolLocator Assembly (Red)Locator Assembly (Yellow)Locator Assembly (Gray)Spring, ReturnSpring, RatchetQuantityFigure 131111121RATCHETRELEASE LEVERFigure 133Visit our Web site at http://www.molex.comDoc No: ATS-638191100Revision: BRelease Date: 01-09-08Revision Date: 08-07-12UNCONTROLLED COPYPage 9 of 9

Crimping Terminals 1. Select the desired terminal listed from the preceding charts and install the proper locator (See chart above and see Locator Installation on page 5). 2. Make sure the center of the locator is in the down pos