handcrimptoolforcommoningcrimpterminals docno:ats638250500 releasedate:021411 uncontrolled copy page1of7 revision:a revisiondate:021411 brush strip length bell mouth conductor crimp height bend down bend up rolling conductor crimp twisting cut-off tab seam insulation crimp type 4d hand crimp tool application tooling specification sheet order no. 63825-0500 features afullcycleratchetinghandtoolensurescomplete crimps ergonomicsoftgriphandlesforcomfortablecrimpin g aprecisionuserfriendlyterminallocatorwiresto pholdsterminalsinthepropercrimpingposition rightandlefthandedapplications thistooliswhmaipca620class2compliantasindi cated thistoolisrohscompliant,howeverrohscompliant isnotrequired scope products :commoningterminals,2830awg. terminal series no. terminal order no. wire size % insulation diameter strip length loose piece + reel awg mm2 mm in. mm in. 14576 05020092 05020091 2830 0.09.055 0.900 .80 .035.031 3.965.54 .156.218 + customertocutoffterminalfromreel:0.18mm(.00 7)maximumcutofftab. % to achieve ipc-a-620 class 2 crimps, the following wire insulation diameter limits are recommended: 1. 28awg0.89mm(.035inch)ul1061. 2. 30awg0.81mm(.032inch)ul1061. forcrimping2426awgwireuse638231200handcr imptool. definition of terms
handcrimptoolforcommoningcrimpterminals docno:ats638250500 releasedate:021411 uncontrolled copy page2of7 revision:a revisiondate:021411 locator in down postion push on the locator button figure 2 insulation crimp note : duetotheterminalsinsulationgripdesign and/orinsulationdiameterrange,thistool usesoverlapformgeometryinthe insulationpunch.thisproducesanoverlap insulationcrimp(a620Ccompliant).while theinsulationpunchprofilemayappear lopsided,thisisanormalconditionforthis tool.seefiguretotheright.(sometools withmultiplecrimppocketsmaynothave theoverlapprofileonallpockets). conditions: aftercrimping,theconductorprofilesshouldmeasu rethefollowing. terminal series no wire size conductor crimp insulation crimp awg mm 2 height (ref.) width (ref.) height (ref.) width (re f.) 14576 28 0.09 0.890.91 .035 .036 1.10 .043 1.65max .065max. 1.55 .061 30 0.055 0.860.89 .034 .035 1.10 .043 1.65max .065max. 1.35 .053 terminal series no wire size pull force minimum profile awg mm 2 n lb. 28 30 14576 28 0.09 11.2 2.5 x 30 0.055 4.4 1.0 x toolqualificationnotes: 1. pullforceshouldbemeasuredwithnoinfluence fromtheinsulationcrimp. 2. theabovespecificationsareguidelinestoanop timumcrimp. operation caution: installonlymolexterminalslistedabovewiththis tool.donotcrimp hardenedobjectsasdamagecanoccurtothetoolor die. openthetoolbysqueezingthehandlestogether.a tthe endoftheclosingstroke,theratchetmechanismwi ll releasethehandlesandthehandtoolwillspringo pen. seefigure1. crimping terminals 1. selectthedesiredterminal,listedintheprecedin g charts.installtheproperlocator(seechartabov e andseelocatorinstallationonpage5). 2. makesurethecenterofthelocatorisinthedown position.withthelocatorattached,pushtheloca torbuttononthebackofthe handtooltobringthelocatorforwardthroughthe tooling.seefigure2. squeeze handles together handle will spring open figure 1 overlap insulation crimp overlap form geometry anvil punch wire
handcrimptoolforcommoningcrimpterminals docno:ats638250500 releasedate:021411 uncontrolled copy page3of7 revision:a revisiondate:021411 terminal figure 3 locator pushed thru tooling terminal release locator button locator button pushed in pre-stripped wire terminal figure 5 terminal wire against the wire stop wire wire stop is part of the locator 3. whileholdinginthelocatorbutton,loadthetermi nalintothepropernest openinginthelocatorbasedonthewiregaugeort erminaltype markingsonthehandtooling.seefigure3. 4. releasethelocatorbutton,allowingthelocatorto returntothecrimping position. 5. closethetoolhandleuntilthefirstratchetposit ionengages.seefigure 4. 6. inserttheproperlystrippedwirethroughthetermi nalandagainstthe wirestop.seefigure5. 7. crimptheterminalbysqueezingthetoolhandlesun tiltheratchet mechanismcyclehasbeencompleted.releasetheha ndlestoopen thejaws. note:thetamperproofratchetactionwillnotrele asethetooluntilithasbeenfullyclosed. 8. removethecrimpedterminalfromtheterminal locatorbypullingonthewire. 9. visuallyinspectthecrimpedterminalforproper crimplocation. 10. onsomelargeo.d.wires,itmaynotbepossibleto insertthewirewiththetoolpartiallyclosed.th ose wiresshouldbeinsertedwiththehandtoolinthe openposition.insertthewireabovetheterminal in thepunchandagainstthewirestopthenclosethe tool.seefigure6. terminal figure 6 wire wire stop partially close handle tooling partially closed figure 4 first ratchet position open position
handcrimptoolforcommoningcrimpterminals docno:ats638250500 releasedate:021411 uncontrolled copy page4of7 revision:a revisiondate:021411 figure 8 push on handle jaws open pull open tooling tooling m3 bhcs squeeze here locator figure 7a squeeze here top hooks top slots of handtool lower tabs make sure center of locator is in the down position figure 7b note: acrimpheightchartisprovidedwiththismanuala sreferenceonly. duetothewiderangeofwires,strands, insulationdiameters,anddurometersavailable,act ualcrimpheightmeasurementsmayveryslightly.a n occasional,destructive,pullforcetestshouldbe preformedtocheckhandtoolcrimp.pullforceval uemust exceed theminimumpullforcespecificationslisted. locator installation seethepartslistonthelastpageofthisdocumen tfortheproperlocatorordernumber.followthe stepsbelowto replacethelocator. 1. openthecrimphandtool. 2. squeezegentlyonthelowerareashowninfigure7a withyourthumbandindexfinger.thelowertabs ofthe locatorshoulddisengagefromthehandtool. 3. liftandpullawayfromthehandtool.thetop locatorhooksshouldslipoutofthetopslotseasi ly. seefigure7a. 4. toreinstallthenewlocator,makesurethehand toolisintheopenposition. 5. presstheredinsertdownasfarasitwillgoas showninfigure7b. 6. holdingontothelowerpartofthelocatorwithyou r thumbandindexfinger,insertthelocatortophook s (2)intothehandtooltopslots. 7. rotatethelocatordownandpressthelowertabsin tothetwobottomslotsofthehandtool.tosecur ethe locatorintoplace,thelowertabsmustsnapintop laceonthehandtoolframe. match up marks front back figure 9
handcrimptoolforcommoningcrimpterminals docno:ats638250500 releasedate:021411 uncontrolled copy page5of7 revision:a revisiondate:021411 right or left hand operation thishandtoolhasanaddedfeaturethatcanbecon vertedfromarighthanded applicationtoalefthandedapplication.itisne cessarytoreversethetooling alongwiththelocatorifusingthelefthandedapp lication.followthesteps below: 1. thelocatormustberemovedbeforereversingtheto oling. 2. removethem3bhcswhichisholdingtheuppertooli ng. 3. fliptheuppertoolingtotheoppositesideandrep lacethem3bhcsmake surethesmallmarkingsonthefrontandbackofth ehandtoolframematch upandareontheoutsideofthehandtoolframe. seefigure8and9. 4. dothesamethingwiththelowertoolingandtighte nthem3screws.besure thesmallmarkingslineup. 5. reinstallthelocatorbyfollowingtheinstructions inthelocatorreplacementsection. maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,andresponsiblefor,thefollowing maintenance steps: 1. removedust,moisture,andothercontaminantswith acleanbrush,orsoft,lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. 3. makecertainallpins;pivotpointsandbearingsur facesareprotectedwithathincoatofhighqualit ymachine oil.donotoilexcessively.thetoolwasenginee redfordurabilitybutlikeanyotherequipmentit needs cleaningandlubricationforamaximumservicelife oftroublefreecrimping.lightoil(suchas30w eight automotiveoil)usedattheoilpoints,every5,000 crimpsor3months,will significantlyenhancethetoollife. 4. wipeexcessoilfromhandtool,particularlyfromc rimpingarea.oil transferredfromthecrimpingareaontocertainter minationsmayaffect theelectricalcharacteristicsofanapplication. 5. whentoolisnotinuse,keepthehandlesclosedto preventobjectsfrom becominglodgedinthecrimpingdies,andstorethe toolinaclean,dry area. miscrimps or jams shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, do not forcethehandlesopenor closed. thetoolwillopeneasilybypressingupontherat chetreleaseleverinthemovablehandle.seefigu re11 how to adjust tool preload (see figure 10) thishandtoolisfactorypresetto2545lbs.prel oad.itmaybenecessaryoverthelifeofthetool toadjusttool handlepreloadforce.listedbelowarethestepsr equiredtoadjustthecrimpingforceofthehandto oltoobtain propercrimpconditions: ratchet release lever figure 11 lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 10
handcrimptoolforcommoningcrimpterminals docno:ats638250500 releasedate:021411 uncontrolled copy page6of7 revision:a revisiondate:021411 figure 12 squeeze the link in the handle hold the hand tool in position setting wheel ratchet release lever 1. holdthehandtoolinthepalmofyour handasshowninfigure12.using theindexfingersqueezethelink towardsthetopofthehandtoolframe. thiswillreleasethepreload adjustmentwheel. 2. rotatethesettingwheelcounter clockwise(ccw)toincreasehandle force.thenumberswilldisplay higher.todecreasehandleforce, rotatethesettingwheelclockwise (cw). 3. releasethelinktolockthesetting wheelinplace. 4. checkthecrimpspecificationsor conductapulltestaftertoolhandle preloadforceisadjusted. warranty thistoolisforelectricalterminalcrimpingpurpo sesonly.thistoolismadeofthebestqualityma terials.allvital componentsarelonglifetested.alltoolsarewar rantedtobefreeofmanufacturingdefectsforape riodof30 days.shouldsuchadefectoccur,wewillrepairo rexchangethetoolfreeofcharge.thisrepairor exchangewill notbeapplicabletoaltered,misused,ordamagedt ools.thistoolisdesignedforhanduseonly.an yclamping, fixturing,oruseofhandleextensionsvoidsthisw arranty. caution :molexcrimpspecificationsarevalidonlywhenu sedwithmolexterminalsandtooling. cautions: 1. manuallypoweredhandtoolsareintendedforlowvo lumeorfieldrepair.thistoolis not intendedfor productionuse.repetitiveuseofthistoolshould beavoided. 2. insulatedrubberhandlesarenotprotectionagainst electricalshock. 3. weareyeprotectionatalltimes. 4. useonlythemolexterminalsspecifiedforcrimping withthistool. certification molexdoesnotcertifyorrecertifyhandtoolsbut rathersuppliesthefollowingguidelinesforcusto merstorecertify handtools. % thistoolisqualifiedtopullforceonly.torec ertify,crimpaterminaltoawire,whichhasbeen stripped 12.7mm(1/2)long,sothereisnocrimpingofthe insulation.pulltheterminalandwireataraten ofasterthan 25mm(1.00)perminute.seethemolexwebsitefo rthequalitycrimphandbookformoreinformationo npull testing. % ifthetooldoesnotmeetminimumpullforcevalues ,handlepreloadshouldbeincreasedandthepullt est rerun,(seehowtoadjustpreload). % whenthehandtoolisnolongercapableofachievin gminimumpullforce,itshouldbetakenoutofser viceand replaced.
handcrimptoolforcommoningcrimpterminals docno:ats638250500 releasedate:021411 uncontrolled copy page7of7 revision:a revisiondate:021411 ratchet release lever 2 figure 13 1 3 parts list item number order number description quantity ref 638250500 handcrimptool figure13 1 638250575 locatorassembly 1 2 638100104 spring,return 1 3 638100105 spring,ratchet 1 http://www.molex.com
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