0638115276

Tool Kit for SPOX™ Crimp Terminals Tool Kit Order No. 63811-5270 Application Tooling Specification Sheet TYPE 2C Hand Crimp Tool Order No. 63811-5200 FEATURES A full cycle ratcheting hand tool ensures complete crimps % Ergonomically designed soft handles % Precisely designed crimping profiles with simple contact 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 installed 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 compliant. % SCOPE Products: 2.50mm (.098”) Pitch SPOX™ Wire-to-Board and Wire-to-Wire Crimp Terminal, 22-28 AWG. Terminal Series No. 5103 5263 45627 50802 Terminal Order No. Wire Size
Insulation Diameter Loose Piece Reel AWG mm² mm In. 08-70-0057 08-70-0056 39-00-0188 08-70-0059 08-70-0058 39-00-0387 39-00-0189 08-700-0569 39-00-0388 22-28 0.35-0.08 1.15-1.90 .045-.075 08-700-0589 39-00-0389 39-00-0390 08-70-1040 08-70-1039 39-00-0151 08-70-1046 08-70-1045 39-00-0159 22-28 0.35-0.08 1.15-1.90 .045-.075 39-00-0152 39-00-0160 45627-1002 45627-0002 22-24 0.35-0.20 1.15-1.90 .045-.075 45627-9002 50802-8100 50802-8000 22-24 0.35-0.20 1.15-1.90 .045-.075 50802-9101 50802-9001 Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.
See Conditions on page 2. Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Strip Length mm In. 3.30-3.80 .130-.150 3.30-3.80 .130-.150 3.30-3.80 .130-.150 3.30-3.80 .130-.150 Page 1 of 9 Tool Kit for SPOX™ Crimp Terminals BEND UP DEFINITION OF TERMS BRUSH BELL MOUTH CONDUCTOR CRIMP INSULATION CRIMP ▲SEE NOTE 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. OVERLAP FORM ▲Insulation Crimp Note: PUNCH GEOMETRY 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). CONDITIONS: OVERLAP INSULATION CRIMP ANVIL WIRE After crimping, the conductor profiles should measure the following (See notes below). Terminal Series No. 5103 5263 50802 45627
Conductor Crimp Insulation Crimp Pull Force Hand Wire Size
Profile Tool Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Minimum Locator AWG mm2 mm In. mm In. mm In. mm In. N Lb. A B C 1 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X 1 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X 1 26 0.12 0.63-0.69 .025-.027 1.40 .055 1.42 .056 1.50 .059 17.79 4.0 X 1 28 0.08 0.61-0.67 .024-.026 1.40 .055 1.42 .056 1.50 .059 11.12 2.5 X 1 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X 1 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X 1 26 0.12 0.63-0.69 .025-.027 1.40 .055 1.42 .056 1.50 .059 17.79 4.0 X 1 28 0.08 0.61-0.67 .024-.026 1.40 .055 1.42 .056 1.50 .059 11.12 2.5 X 1 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X 1 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X 1 26 0.12 0.63-0.69 .025-.027 1.40 .055 1.42 .056 1.50 .059 17.79 4.0 X 1 28 0.08 0.61-0.67 .024-.026 1.40 .055 1.42 .056 1.50 .059 11.12 2.5 X 2 22 0.35 0.73-0.80 .029-.031 1.40 .055 1.68 .066 1.90 .075 44.48 10.0 X 2 24 0.20 0.67-0.74 .026-.029 1.40 .055 1.57 .062 1.90 .075 28.91 6.5 X To Achieve IPC-A-620 Class 2 crimps. The following over-all wire insulation diameter ranges are recommended: 1. Profile A: 1.20-1.90mm (.047-.075 inch) 2. Profile B: 1.20-1.55mm (.047-.061 inch) 3. Profile C: 1.15-1.30mm (.045-.051 inch) Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Page 2 of 9 Tool Kit for SPOX™ Crimp Terminals 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 manual as Reference Only. Due to the wide range of wires, strands, insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional, 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. JAWS OPEN INSTALLATION To install the Tool Kit into the Power Crimp Head follow the steps below: LOCATOR 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. Locator Installation and Removal Figure 3 Follow the steps below to install or replace the locator. See Figure 2. To install the locator 1. Position the locator with the hole over the brass pivot shaft and snap it into place. To remove the locator 1. Open the crimp hand tool. 2. Swing the existing locator open and away from the hand tool. 3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the top of the brass pivot shaft. TERMINAL SWING OPEN OPERATION PUSH HERE TO OPEN WIRE STOP LOCATOR LOCATOR Open the tool by squeezing the handles Figure 4 together, at the end of the closing stroke, the ratchet mechanism will release the handles, and the hand tool will spring open. TERMINAL IN PLACE Crimping Terminals 1. Select the desired terminal listed in the preceding charts. Make sure that the proper locator is mounted on the tool. Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Page 3 of 9 Tool Kit for SPOX™ Crimp Terminals 2. Swing the terminal locator away from the crimp tool shown in Figure WIRE STOP 4. Some terminals with large insulation grips may interfere with the crimp tooling when swinging the locator into position. The terminal WIRE must then be loaded into the locator in the closed/crimp position. 3. When using the locator, press down on the wire stop on the locator as shown in Figure 4. Insert the proper terminal into the proper nest opening. Make sure when choosing the nest opening, it will correspond with the A, B, or C profile on the hand tool. 4. Return the locator to its original position. LOCATOR TERMINAL 5. Insert the proper wire over the terminal. Some large O.D. wires may IN PLACE need to be placed into the terminal before closing the tool. Gently touch the wire stop with the end of the wire. See Figure 5. 6. Compress the terminal by squeezing the tool handles until the WIRE STOP ratchet mechanism cycle has been completed. Release handles to open the jaws. 7. Return the locator to its original position. WIRE AGAINST 8. Insert the proper wire over the terminal. Some large O.D. wires may Figure 5 STOP need to be placed into the terminal before closing the tool. Gently touch the wire stop with the end of the wire. See Figure 5. 9. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release handles to open the jaws. 10. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on the wire. The terminal locator can be in either position. 11. Visually inspect the crimped terminal for proper crimp location. Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 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 can be in either position. 3. Visually inspect the crimped terminal for proper crimp location. Locator Change Over and Replacement Multiple styles of locators maybe provided with the crimp hand tool. They are different colors for easy identification. See the parts list on the last page of the document. Make sure the desired style of locator is installed for the proper terminal and wire. Follow the steps below to change the locators. LIFT UP LOCATOR JAWS OPEN PRESS DOWN ON BRASS PIVOT SHAFT SWING LOCATOR OPEN Figure 6 1. Open the crimp hand tool. 2. Swing the existing locator open and away from the hand tool. Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Page 4 of 9 Tool Kit for SPOX™ Crimp Terminals 3. Firmly press down on the brass pivot shaft with your thumb, while pulling the locator up. Slip the locator off the top of the brass pivot shaft. See Figure 6. 4. Replace it with the desired locator by putting over the brass pivot shaft and snapping it into place. Figure 7B LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY MONTH OR 5,000 CRIMPS) 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 Figure 7A 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 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 7A or 7B 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 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. PRELOAD CHECK POINT 25.4MM 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 8. SETTING WHEEL ECCENTRIC AXLE How to Adjust Tool Preload (See Figure 8) 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: HANDLE GRIP REMOVED WRENCH SET (SOLD SEPERATELY) LOCKING SCREW HANDLE GRIP RATCHET RELEASE LEVER Figure 8 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. The 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 increase handle force. Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Page 5 of 9 Tool Kit for SPOX™ Crimp Terminals 4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw. 5. Replace the handle grip. 6. Check the crimp specifications or conduct a pull test after tool handle preload force is adjusted. 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. 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 commercial grade hand tools but rather supplies the following guidelines for customers to re-certify hand tools. % This tool is qualified to pull force only. To re-certify, 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 no faster than 25mm (1.00”) per minute. 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. The chart below shows all applications for this Tool Kit. Tool Kit Order No. Tool Tool Power Head Adapter Figure Order no. Description Order No. Description No. 63810-0100 Hand Crimp Frame (Short) N/A N/A 9 63810-0400 Hand Crimp Frame (Long) N/A N/A 9 63811-5270 63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head 10 63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head 10 Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Page 6 of 9 Tool Kit for SPOX™ Crimp Terminals Applications for the Tool Kit Hand Crimp Tool Battery Powered Tool POWER CRIMP HEAD TOOLING KIT TOOLING KIT HAND CRIMP FRAME LONG AND SHORT BATTERY POWERED TOOL Figure 9 LOCKING PINS Figure 10 WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper instruction and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See Chart above for the correct Manual or Specification Sheet. WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the power is turned off. CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury. CAUTION: Wear safety glasses when operating or serving this tool. Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Page 7 of 9 Tool Kit for SPOX™ Crimp Terminals HAND TOOL PARTS LIST Item Number 1 2 3 4 5 6 7 Order Number 63810-0100 63810-0101 63810-0102 63810-0103 63811-5270 63811-5275 63811-5276 6 LOCATOR ONLY 5 WITH TOOL KIT 7 LOCATOR ONLY 5 WITH TOOL KIT Description Hand Crimp Frame (Short) Wrench Set (Not included) Locator Base Repair Kit (Not included) Tool Kit with Locator Locator #1-Black Locator #2-Gray Quantity 1 0 1 0 1 1 1 2 4 3 1 RATCHET RELEASE SCREW M4 X 6mm LONG BHCS 4 5 M4 X 12mm LONG BHCS Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 Figure 11 M4 X 12mm LONG BHCS UNCONTROLLED COPY Page 8 of 9 Tool Kit for SPOX™ Crimp Terminals POWER HEAD PARTS LIST Item 1 2 Order No 63816-0300 63811-5270 Engineering No. 63816-0300 63811-5270 Description Power Crimp Head Tool Kit Quantity 1 1 2 1 1 M4 by 8 Long BHCS M4 by 18 Long BHCS M4 by 10 Long BHCS 2 Figure 12 http://www.molex.com Doc No: ATS-6381152HM Release Date: 04-03-06 Revision: D Revision Date: 06-30-11 UNCONTROLLED COPY Page 9 of 9