tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 1 of 8 revision: b revision date: 10-04-10 strip length insulation crimp seam wire conductor crimp application tooling specification sheet tool kit order no. 63819-3270 hand crimp tool order no. 63819-3200 features % a full cycle ratcheting hand tool ensures complete crimps % ergonomically designed soft handles % precisely designed crimping profiles with simple co ntact 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 in stalled 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 compli ant. scope products : quick disconnect, female, flag, for 0.50 and 0.80 mm2 (20 and 18 awg) wires. terminal series no. terminal order no. wire size insulation diameter strip length reel awg mm2 mm in. mm in. 94030 94030-5000 94030-5001 0.50 2.10-2.60 .083-.102 6.0-7.0 .236-.276 20 (0.52) 0.80 18 (0.82) customer to cut off terminal from reel. cut tab fl ush with terminal on both ends. definition of terms type 2c
tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 2 of 8 revision: b revision date: 10-04-10 anvils power crimp head figure 1 punches m4 x 10 long bhcs m4 x 18 long bhcs conditions: after crimping, the conductor profiles should measu re the following (see notes below). terminal series no. wire size conductor crimp profile height (ref.) width (ref.) awg mm 2 mm in. mm in. a b 94030 0.50 1.40 - 1.50 .055 - .059 2.35 .093 x 20 (0.52) 1.40 - 1.50 .055 - .059 2.35 .093 x 0.80 1.50 C 1.60 .059 - .063 2.35 .093 x 18 (0.82) 1.50 C 1.60 .059 - .063 2.35 .093 x terminal series no. wire size insulation crimp pull force minimum height (ref.) width (ref.) awg mm 2 mm in. mm in. n lb. 94030 0.50 2.80 C 2.90 .110 - .114 3.45 max .136 max 78. 45 17.6 20 (0.52) 2.80 C 2.90 .110 - .114 3.45 max .136 max 78.45 17.6 0.80 2.90 C 3.00 .114 - .118 3.45 max .136 max 117 .68 26.4 18 (0.82) 2.90 C 3.00 .114 - .118 3.45 max .136 max 117.68 26.4 tool qualification notes: 1. pull force should be measured with no influence from the insulation crimp. 2. the above specifications are guidelines to an op timum crimp. note: a crimp height chart is provided with this manual a s reference only. due to the wide range of wires, strands, insulation diameters, and durometers, actual crimp height measurements may very slightly. an occasion al, 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.
tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 3 of 8 revision: b revision date: 10-04-10 figure 2 jaws open terminal knurled fastener upper tooling 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. select the desired terminal listed in the preceding charts. 2. before attempting to crimp any terminals, make sure all the upper tooling is correctly placed into the upper jaw. th e desired nest being used for the proper wire size should be in th e forward position, (the marking on the upper tooling a for 0.8mm 2 or b for 0.5mm 2 ). this is done by removing the knurled fastener t hat holds the upper tooling in place and then rotating it 180 to the correct position. then, re-installing the fastener. see figure 2. 3. place the terminal into the nest profile, centered on the nest as shown, with the outer edges of the c rimp grips flush with each side of the crimp die and the openi ng in the terminal centered below the forward leg o f the right punch. see figure 3. 4. partially close the tool until the terminal is held in place and re-position the terminal as necessary . 5. from the left side of the tool , insert the pre-stripped wire into the terminal un til the conductor is centered, front to rear, in the crimp grips. see figure 3. 6. compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been complet ed. release handles to open the jaws. note: the tamper proof ratchet action will not release t he tool until it has been fully closed. 7. remove the crimped terminal. inspect for proper crimp location, and check for insulation closure. 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 c an be in either position. 3. visually inspect the crimped terminal for proper crimp location. 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. figure 3 note : the terminal should be centered in crimp nests with the outer edges of the crimp grips flush with the jaws on both sides. wire conductor of the terminal centered in crimp grips front to rear see note below see note below
tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 4 of 8 revision: b revision date: 10-04-10 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. use a 30 weight automotive (light) oil used at the oil points, every 5,000 crimps or 3 months, shown in figure 4a or 4b 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 char acteristics 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 pressing the ratchet release lever. see figure 5. how to adjust tool preload (see figure 5) 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 condi tions: 1. remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel. 2. remove the locking screw with a 2mm hex wrench. th e wrench set (63810-0101), is not supplied. it is sold separately from the hand tool. 3. turn the eccentric axle and setting wheel with the wrench or pliers counter-clockwise (ccw) to increas e handle force. 4. replace the locking screw, aligning the nearest not ch in the setting wheel to locking screw. 5. replace the handle grip. 6. check the crimp specifications or conduct a pull te st after tool handle preload force is adjusted. warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life tested. all tools are war ranted to be free of manufacturing defects for a pe riod of 30 ratchet release lever figure 5 handle grip removed eccentric axle handle grip locking screw wrench set (sold seperately) preload check point 25.4mm setting wheel lubrication points (both sides) light oil (every month or 5,000 crimps) figure 4a figure 4b
tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 5 of 8 revision: b revision date: 10-04-10 days. should such a defect occur, we will repair o r exchange the tool free of charge. this repair or exchange will not be applicable to altered, misused, or damaged t ools. this tool is designed for hand use only. an y clamping, fixturing, or use of handle extensions voids this w arranty. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling. cautions 1. manually powered hand tools are intended for low vo lume 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 commercial gra de hand tools but rather supplies the following gui delines for customers to re-certify hand tools. % this tool is qualified to pull force only. to re-c ertify, 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 n o faster than 25mm (1.00) per minute. see the molex web site fo r the quality crimp handbook for more information o n pull testing. % if the tool does not meet minimum pull force values , handle preload should be increased and the pull t est rerun, (see how to adjust preload). % when the hand tool is no longer capable of achievin g minimum pull force, it should be taken out of ser vice and replaced.
tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 6 of 8 revision: b revision date: 10-04-10 the chart below shows all applications for this too l kit. tool kit order no. tool order no. tool description power head order no. adapter description figure no. 63819-3270 63810-0100 hand crimp frame (short) n/a n/a 6 63810-0400 hand crimp frame (long) n/a n/a 6 63816-0200 battery power tool (110 v) 63816-0300 power crimp head 7 63816-0250 battery power tool (220 v) 63816-0300 power crimp head 7 applications for the tool kit hand crimp tool battery powered tool figure 6 figure 7 warning : never operate service, install tool kits, or adjust the p ower crimp head without proper instruction and without first reading and understan ding the instructions in the proper manual or specification sheet. see chart above for the corre ct manual or specification sheet. warning : never install tooling or service this tool while it is in to any power source. make sure the power is turned off. caution: keep fingers away from the crimping area when opera ting this tool. it may cause severe injury. caution: wear safety glasses when operating or serving this tool. power crimp head locking pins battery powered tool tooling kit hand crimp frame long and short tooling kit
tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 7 of 8 revision: b revision date: 10-04-10 ratchet release screw figure 8 1 3 m4 x 12mm long bhcs knurled fastener 3 4 2 hand tool parts list item number order number description quantity 1 63810-0100 hand crimp frame (short) 1 2 63810-0101 wrench set (not included) 0 3 63810-0103 repair kit (not included) 0 4 63819-3270 tool kit 1
tool kit for quick disconnect, female, flag crimp t erminals doc no: ats-6381932hm release date: 03-23-09 uncontrolled copy page 8 of 8 revision: b revision date: 10-04-10 figure 9 1 2 m4 by 18 long bhcs m4 by 10 long bhcs power head parts list item order no engineering no. description quantity 1 63816-0300 63816-0300 power crimp head 1 2 63819-3270 63819-3270 tool kit 1 http://www.molex.com
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