hand crimp tool for 3.7 led plug male crimp termina ls doc no: ats-638235800 release date: 07-09-10 uncontrolled copy page 1 of 7 revision: a revision date: 07-09-10 insulation crimp brush strip length bell mouth crimp height bend down bend up rolling conductor crimp twisting hand crimp tool application tooling specification sheet order no. 63823-5800 features a full cycle ratcheting hand tool ensures complete crimps ergonomic soft grip handles for comfortable crimpin g a precision user-friendly terminal locator wire sto p holds terminals in the proper crimping position right and left handed applications this tool is ipc/whma a-620 class 2 compliant as in dicated this tool is rohs compliant, however rohs compliant is not required scope products : 3.7 led plug male crimp terminals, 26-28 awg. terminal order no. wire size insulation diameter st rip length terminal series no. loose piece reel awg mm2 mm in. mm in. 503485 503485-0000 26-28 0.14-0.079 .093-1.14 .004-.045 1.30-1.50 .051-.059 customer to cut off terminal from reel: 0.15m (.006 ) maximum cut-off tab. definition of terms the above terminal drawing is a generic terminal re presentation. it is not an image of a terminal lis ted in the scope. type 4d
hand crimp tool for 3.7 led plug male crimp termina ls doc no: ats-638235800 release date: 07-09-10 uncontrolled copy page 2 of 7 revision: a revision date: 07-09-10 release locator button terminal figure 3 locator pushed thru tooling terminal locator button pushed in locator conditions: after crimping, the conductor profiles should measu re the following. conductor crimp wire size height (ref.) width (ref.) profile terminal series no. awg mm 2 mm in. mm in. 26 28 26 0.14 0.56-0.61 .022-.024 0.85-0.95 .033-.037 x 503485 28 0.08 0.53-0.58 .020-.023 0.85-0.95 .033-.037 x insulation crimp wire size height (ref.) width (ref.) pull force minimum terminal series no. awg mm 2 mm in. mm in. n lb. 26 0.14 1.30-1.50 .051-.059 1.35-1.45 .053-.057 9.8 2.20 503485 28 0.08 1.30-1.50 .051-.059 1.35-1.45 .053-.057 9.8 2.20 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. see figure 1. crimping terminals 1. select the desired terminal listed in the preceding charts. 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 ma rkings on the hand tooling. see figure 3. locator in down postion push on the locator button figure 2 squeeze handles together handle will spring open figure 1
hand crimp tool for 3.7 led plug male crimp termina ls doc no: ats-638235800 release date: 07-09-10 uncontrolled copy page 3 of 7 revision: a revision date: 07-09-10 pre-stripped wire terminal figure 5 terminal wire against the wire stop wire wire stop is part of the locator 4. release the locator button, allowing the locator to return to the crimping position. 5. close the tool handle until the first ratchet posit ion engages. see figure 4. 6. insert the properly stripped wire through the termi nal and against the wire stop. see figure 5. 7. crimp the terminal by squeezing the tool handles un til the ratchet mechanism cycle has been completed. release the ha ndles to open the jaws. note: the tamper proof ratchet action will not rele ase the tool until it has been fully closed. 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. 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 available, act ual crimp height measurements may very slightly. a n occasional, destructive, pull force test should be performed to check hand tool crimp. pull force val ue must exceed the minimum pull force specifications listed . locator replacement see the parts list on the last page of this documen t for the proper locator order number. follow the steps below to replace the locator. terminal figure 6 wire wire stop partially close handle tooling partially closed figure 4 first ratchet position open position
hand crimp tool for 3.7 led plug male crimp termina ls doc no: ats-638235800 release date: 07-09-10 uncontrolled copy page 4 of 7 revision: a revision date: 07-09-10 figure 8 push on handle jaws open pull open tooling tooling m3 bhcs match up marks front back figure 9 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. 2. remove the m3 bhcs which is holding the upper tooling. 3. flip the upper tooling to the opposite side and rep lace the m3 bhcs. make sure the small markings on the front and back of the hand tool frame, match up and are on the outside of the hand tool frame. see fi gure 8 and 9. 4. do the same thing with the lower tooling and tighte n the m3 screws. be sure the small markings line u p. 5. reinstall the locator by following the instructions in the locator replacement section. maintenance it is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: make sure center of locator is in the down position figure 7b squeeze here squeeze here locator figure 7a top hooks top slots of handtool lower tabs
hand crimp tool for 3.7 led plug male crimp termina ls doc no: ats-638235800 release date: 07-09-10 uncontrolled copy page 5 of 7 revision: a revision date: 07-09-10 figure 12 squeeze the link in the handle hold the hand tool in positi n setting wheel ratchet release lever 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 sur faces are protected with a thin coat of high quality machine oil. do not oi l excessively. the tool was engineered for durability but like any other eq uipment 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 signif icantly enhance the tool life. 4. wipe excess oil from hand tool, particularly from c rimping area. oil transferred from the crimping area onto certain ter minations 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 p artially 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 mov able handle. see figure 11. how to adjust tool preload (see figure 12) this hand tool is factory preset to 25-45 lbs. prel oad. it may be necessary over the life of the tool to adjust tool handle preload force. listed below are the steps r equired to adjust the crimping force of the hand to ol to obtain proper crimp conditions: 1. hold the hand tool in the palm of your hand as shown in figure 10. 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. lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 10 ratchet release lever figure 11
hand crimp tool for 3.7 led plug male crimp termina ls doc no: ats-638235800 release date: 07-09-10 uncontrolled copy page 6 of 7 revision: a revision date: 07-09-10 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 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 hand tools but rather supplies the following guidelines for custo mers 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.
hand crimp tool for 3.7 led plug male crimp termina ls doc no: ats-638235800 release date: 07-09-10 uncontrolled copy page 7 of 7 revision: a revision date: 07-09-10 ratchet release lever 2 figure 13 1 3 parts list item number order number description quantity ref 63823-5800 hand crimp tool figure 13 1 63823-5875 locator assembly 1 2 63810-0104 spring, return 1 3 63810-0105 spring, ratchet 1 http://www.molex.com
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