0638239000

Hand Crimp Tool For SATA Power Cable Crimp Receptacles HAND CRIMP TOOL Application Tooling Specification Sheet TYPE 4D Order No. 63823-9000 FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
Right and Left handed applications
This tool is IPC/WHMA A-620 Class 2 compliant
This tool is RoHS compliant, however RoHS compliant is not required SCOPE Products: SATA Slim Line Crimp Receptacles, 18-24 AWG. Terminal Order No. Wire Size and Type Insulation Diameter Strip Length
Reel AWG mm² mm In. mm In. 47634-1000 47634-1001 47634 18-24 UL1007 1.25-2.40 .049-.094 3.50 .138 47634-1002 47634-0009
Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab. Terminal Series No. DEFINITION OF TERMS STRIP LENGTH BRUSH BEND UP SEAM TWISTING ROLLING BEND DOWN Doc No: ATS-638239000 Revision: A LANCE HEIGHT Release Date: 03-07-11 Revision Date: 03-07-11 BELL MOUTH CONDUCTOR CRIMP HEIGHT INSULATION CRIMP HEIGHT UNCONTROLLED COPY CUT-OFF TAB Page 1 of 7 Hand Crimp Tool For SATA Power Cable Crimp Receptacles ▲Insulation Crimp Note: 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). OVERLAP FORM GEOMETRY PUNCH OVERLAP INSULATION CRIMP CONDITIONS: ANVIL WIRE After crimping, the conductor profiles should measure the following. Terminal Series No 47634 Wire Size AWG 18 20 22 24 mm2 UL1007 UL1007 UL1007 UL1007 Conductor Crimp Height Width (Ref.) mm In. mm In. 1.15-1.25 .045-.049 1.55-1.65 .061-.065 1.10-1.20 .043-.047 1.55-1.65 .061-.065 1.05-1.15 .041-.045 1.55-1.65 .061-.065 0.97-1.07 .038-.042 1.55-1.65 .061-.065 Insulation Crimp Height Max. Width (Ref.) mm In. mm In. 2.50 .098 2.40 .094 2.50 .098 2.40 .094 2.50 .098 2.20 .087 2.50 .098 2.20 .087 Pull Force Profile Minimum N Lb. 18 20 22 24 88.20 19.8 X 58.80 13.2 X 39.20 8.8 X 29.40 6.6 X 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 available, actual crimp height measurements may very slightly. An occasional, destructive, pull force test should be performed to check hand tool crimp. Pull Force value Must exceed the Minimum pull force specifications listed. 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. Doc No: ATS-638239000 Revision: A Release Date: 03-07-11 Revision Date: 03-07-11 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool For SATA Power Cable Crimp Receptacles LOCATOR IN DOWN POSTION 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 markings on the hand tooling. See Figure 3. 4. Release the locator button, allowing the locator to return to the crimping position. 5. Close the tool handle until the first ratchet position engages. See Figure 4. 6. Insert the properly stripped wire through the terminal and against the wire stop. See Figure 5. 7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release the handles to open the jaws. HANDLE WILL SPRING OPEN Figure 2 Figure 1 PUSH ON THE LOCATOR BUTTON SQUEEZE HANDLES TOGETHER LOCATOR PUSHED THRU TOOLING RELEASE LOCATOR BUTTON LOCATOR LOCATOR BUTTON PUSHED IN Figure 3 TERMINAL TERMINAL Note: The tamper proof ratchet action will not release the tool until it has been fully closed. TOOLING PARTIALLY CLOSED PARTIALLY CLOSE HANDLE TERMINAL WIRE AGAINST THE WIRE STOP WIRE STOP IS PART OF THE LOCATOR OPEN POSITION PRE-STRIPPED WIRE FIRST RATCHET POSITION Figure 4 Doc No: ATS-638239000 Revision: A WIRE Figure 5 Release Date: 03-07-11 Revision Date: 03-07-11 UNCONTROLLED COPY TERMINAL Page 3 of 7 Hand Crimp Tool For SATA Power Cable Crimp Receptacles WIRE 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. WIRE STOP Figure 6 TERMINAL Locator Replacement LOCATOR 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. SQUEEZE HERE MAKE SURE 1. Open the crimp hand tool. CENTER OF LOCATOR SQUEEZE 2. Squeeze gently on the lower area shown in IS IN THE HERE DOWN POSITION Figure 7A with your thumb and index finger. Figure 7A The lower tabs of the locator should disengage TOP SLOTS OF from the hand tool. HANDTOOL 3. Lift and pull away from the hand tool. The top locator hooks should slip out of the top slots TOP HOOKS 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. 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. LOWER TABS 7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To JAWS OPEN secure the locator into place, the lower tabs must snap into place on the hand tool frame. PULL OPEN Right or Left Hand Operation TOOLING TOOLING M3 BHCS 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. Doc No: ATS-638239000 Revision: A Release Date: 03-07-11 Revision Date: 03-07-11 Figure 8 PUSH ON HANDLE UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool For SATA Power Cable Crimp Receptacles 2. Remove the M3 BHCS which is holding the upper MATCH tooling. UP MARKS 3. Flip the upper tooling to the opposite side and replace the M3 BHCS. Make sure the small markings on the front and back of the hand tool frame Figure 9 match up and are on the outside of the hand tool frame. See Figure 8 and 9. 4. Do the same thing with the lower tooling and tighten FRONT the M3 screws. Be sure the small markings line up. 5. Reinstall the locator by following the Instructions in the locator replacement section. BACK 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. 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. LUBRICATION POINTS The tool was engineered for durability but like any other equipment it (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR needs cleaning and lubrication for a maximum service life of trouble 5,000 CRIMPS) free crimping. Light oil (such as 30 weight automotive oil) used at the oil points, every 5,000 crimps or 3 months, will significantly enhance the tool life. Figure 10 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. 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 up on the ratchet release lever in the movable handle. See Figure 11. RATCHET RELEASE LEVER How to Adjust Tool Preload (See Figure 12) 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: Figure 11 Doc No: ATS-638239000 Revision: A Release Date: 03-07-11 Revision Date: 03-07-11 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool For SATA Power Cable Crimp Receptacles 1. Hold the hand tool in the palm of your hand as shown in Figure 12. 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 counterclockwise (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. RATCHET RELEASE LEVER SQUEEZE THE LINK IN THE HANDLE HOLD THE HAND TOOL IN POSITION Figure 12 SETTING WHEEL 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 hand tools but rather supplies the following guidelines for customers to re-certify hand tools. % This tool is qualified to pull force only. 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-638239000 Revision: A Release Date: 03-07-11 Revision Date: 03-07-11 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool For SATA Power Cable Crimp Receptacles PARTS LIST Item Number REF 1 2 3 Order Number 63823-9000 63823-9075 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 2 1 3 Figure 13 http://www.molex.com Doc No: ATS-638239000 Revision: A Release Date: 03-07-11 Revision Date: 03-07-11 UNCONTROLLED COPY Page 7 of 7