0638116475

Tool Kit for Pico-SPOX™ Crimp Terminals TYPE 2C Application Tooling Specification Sheet Tool Kit Order No. 63811-6470 Hand Crimp Tool Order No. 63811-6400 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: 1.50mm (.059") Pico-SPOX™ Crimp Terminal, Female, 24-30 AWG. Terminal Series No. Terminal Order No. Wire Size Available in Reel form only mm² 0.20
Insulation Diameter Maximum mm In. 1.15 .045 AWG Type 24 UL1061 26 UL1061 87421-0000 26-30 0.12-0.05 28 UL1061 1.00 .039 30 UL1571 Customer to cut off terminal from reel: 0.29mm (.011”) maximum Cut-off Tab.
See Conditions on page 2. 87421 AWG 24 Wire Type DEFINITION OF TERMS BRUSH Strip Length mm 1.05-1.54 In. .041-.061 1.05-1.54 .041-.061 BEND UP BELL MOUTH CONDUCTOR CRIMP INSULATION CRIMP ▲SEE NOTE ROLLING TWISTING STRIP LENGTH BEND DOWN CRIMP HEIGHT Doc No: ATS-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 1 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals ▲Insulation Crimp Note: OVERLAP FORM GEOMETRY PUNCH 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). After crimping, the conductor profiles should measure the following (see notes below). OVERLAP INSULATION CRIMP WIRE ANVIL ●Insulation Crimp Conductor Crimp Pull Force
Profile Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Minimum AWG mm2 mm In. mm In. mm In. mm In. N Lb. A B 24 0.20 0.56-0.60 .022-.024 1.00 .039 1.40 .055 1.10 .043 29.4 6.60 X 26 0.12 0.52-0.58 .020-.023 1.00 .039 1.24 .049 1.10 .043 19.6 4.40 X 87421 28 0.08 0.52-0.58 .020-.023 1.00 .039 1.24 .049 1.10 .043 9.8 2.20 X 30 0.05 0.52-0.58 .020-.023 1.00 .039 1.24 .049 1.10 .043 6.7 1.50 X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended: Profile A: 1.00-1.15mm (.039-.045 inch) Profile B: 0.65-1.00mm (.025-.039 inch) Terminal Series No Wire Size 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 this page. 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. Doc No: ATS-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 2 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals POWER CRIMP HEAD PUNCHES M4 X 18 LONG BHCS LIFT UP ON THE LOCATOR PRESS DOWN ON THE BRASS PIVOT SHAFT M4 X 10 LONG BHCS Figure 1 ANVILS SWING LOCATOR OPEN Figure 2 Locator Installation and Removal 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. JAWS OPEN LOCATOR 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. OPERATION Figure 3 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. FRAME SWING OPEN TERMINAL PRESS HERE ON LOCATOR LOCATOR TERMINAL IN PLACE Figure 4 Doc No: ATS-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 3 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals Crimping Terminals 1. Select the desired terminal listed in the preceding charts. 2. Swing the terminal locator away from the crimp tool shown in WIRE STOP Figure 4. Gently press on the locator to open the wire stop. WIRE Some terminals with large insulation grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be loaded into the locator in the closed/crimp position. 3. When using the locator, swing the locator away from the crimp tool, and gently press the locator against the tool frame as shown in Figure 4. The wire stop will automatically open. Insert LOCATOR IN PLACE WIRE STOP TERMINAL the proper terminal into the proper nest opening. Make sure when choosing the nest opening, it will correspond with the A or B profile on the hand tool. 4. Return the locator to its original position. 5. Insert the proper wire over the terminal. Some large O.D. wires may need to be placed into the terminal before closing the tool. Gently touch the wire stop with the end of the wire. See Figure WIRE 5. AGAINST STOP 6. Compress the terminal by squeezing the tool handles until the Figure 5 ratchet mechanism cycle has been completed. Release handles to open the jaws. 7. 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. 8. 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. LIFT UP LOCATOR Locator Replacement See the parts list on the last page of this document for the proper locator order number. Follow the steps below to replace 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. See Figure 6. 4. Replace it with the proper locator by putting over the brass pivot shaft and snapping it into place. JAWS OPEN PRESS DOWN ON BRASS PIVOT SHAFT SWING LOCATOR OPEN Figure 6 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. Doc No: ATS-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 4 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: Figure 7B 1. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth. LUBRICATION POINTS 2. Do not use any abrasive materials that (BOTH SIDES) could damage the tool. LIGHT OIL 3. Make certain all pins; pivot points and (EVERY MONTH bearing surfaces are protected with a thin OR coat of high quality machine oil. Do not oil 5,000 CRIMPS) excessively. The tool was engineered for Figure 7A 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 PRELOAD CHECK POINT lodged in the crimping dies, and store the tool 25.4MM in a clean, dry area. Miscrimps or Jams SETTING WHEEL ECCENTRIC AXLE 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. How to Adjust Tool Preload (See Figure 8) HANDLE GRIP REMOVED WRENCH SET (SOLD SEPERATELY) LOCKING SCREW HANDLE GRIP RATCHET RELEASE LEVER 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: 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. 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. Doc No: ATS-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 5 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals 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. Doc No: ATS-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 6 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals The chart below shows all applications for this Tool Kit. Adapter Figure Tool Tool Power Head Order No. Description No. Order no. Description 63810-0100 Hand Crimp Frame (Short) N/A N/A 9 63810-0400 Hand Crimp Frame (Long) N/A N/A 9 63811-6470 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 Tool Kit Order No. 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-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 7 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals HAND TOOL PARTS LIST Item Number 1 2 3 4 5 6 6 LOCATOR ONLY 5 WITH TOOL KIT Order Number 63810-0100 63810-0101 63810-0102 63810-0103 63811-6470 63811-6475 Description Hand Crimp Frame (Short) Wrench Set (Not included) Locator Base Repair Kit (Not included) Tool Kit with Locator Locator (only) Quantity 1 0 1 0 1 REF 2 4 3 1 M4 X 6mm LONG BHCS RATCHET RELEASE SCREW Figure 11 4 5 M4 X 12mm LONG BHCS Doc No: ATS-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 M4 X 12mm LONG BHCS UNCONTROLLED COPY Page 8 of 9 Tool Kit for Pico-SPOX™ Crimp Terminals POWER HEAD PARTS LIST Item 1 2 Order No 63816-0300 63811-6470 Engineering No. 63816-0300 63811-6470 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-6381164HM Release Date: 06-19-06 Revision: C Revision Date: 10-06-10 UNCONTROLLED COPY Page 9 of 9