0638252275

Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire) Application Tooling Specification Sheet Modular Crimp Head Order No. 63825-2270 TYPE 4A Hand Crimp Tool Order No. 63825-2200 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 Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100, accompanied by Air Powered Crimp Adapter (Order No. 63816-0700). Can also be used in the Battery Powered Tool Order No. 63816-0200 (110 V) or 63816-0250 (220 V) accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600). SCOPE Products: .110 Receptacle Terminals, 23.5, 25.0 and 25.5 AWG Magnet Wires. Terminal Series No. 49748 Magnet Wire Size and Type Bare Wire Insulated AWG Diameter (mm Approximately) CMA Diameter (mm Approximately) CMA 23.5 .541 454 .589 538 49748-9001 25.0 .455 320 .500 388 25.5 .429 286 .475 350 Customer to cut off terminal from reel: 0.50mm (.020”) maximum Cut-off Tab. Terminal Order No. DEFINITION OF TERMS INSULATION CRIMP ▲SEE NOTE CONDUCTOR BRUSH BELL MOUTH INSULATION SLEEVE WIRE BEND UP SEAM CUT-OFF TAB CONDUCTOR CRIMP HEIGHT TWISTING ROLLING Doc No: ATS-6382522HM Revision: A Release Date: 02-10-12 Revision Date: 02-10-12 BEND DOWN UNCONTROLLED COPY Page 1 of 6 Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire) OVERLAP FORM GEOMETRY ▲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). PUNCH OVERLAP INSULATION CRIMP SLEEVE AND WIRE ANVIL CRIMP SPECIFICATIONS: Terminal Series No. 49748 Terminal Series No. Bell mouth mm In. 0.30-0.80 .012-.031 Bend up Bend down 5 Seam Twist Roll Degree 49748 Conductor Brush Max. mm In. 0.50-1.80 .020-.071 5 3 Degree 5 Seam shall not be open and no wire allowed out of the crimping area After crimping, the conductor profile should measure the following. Terminal Series No. 49748 Terminal Series No. 49748 Wire Size AWG 23.5 25.0 25.5 Conductor Crimp Height Width mm In. mm In. 0.98-1.02 .039-.040 0.93-0.97 .037-.039 1.82-1.88 .072-.074 0.88-0.92 .035-.036 N 37.3 24.5 19.6 Lb. 8.4 5.5 4.4 Insulation Crimp Wire Size AWG 23.5 25.0 25.5 Pull Force Minimum Height Width mm In. mm In. 1.55-1.95 .061-.077 2.60-2.70 .102-.106 5.4 to 7.3 INSULATION SLEEVE LOCATION Profile 23.5 AWG 25.0 AWG X x 25.5 AWG X Insulation Sleeve Diameter (Ref) Length (Ref) mm In. mm In. Material Teflon Tubing TFS-19 ~ 21 0.86 .038 10.0 Min .394 Min. INSULATION SLEEVE 10.0 Minimum
Tool Qualification Notes: Reference 1. Pull Force should be measured with no influence from the insulation crimp. 2. The above specifications are guidelines to an optimum crimp. Doc No: ATS-6382522HM Revision: A Release Date: 02-10-12 Revision Date: 02-10-12 UNCONTROLLED COPY Page 2 of 6 Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire) OPERATION 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. WIRE STOP BLADE TERMINAL INSULATION PUNCH CONDUCTOR PUNCH WIRE STOP BLADE INSULATION PUNCH LOCATOR SLEEV AND WIRE TERMINAL WIRE CONDUCTOR ANVIL Crimping Terminals 1. 2. 3. 4. 5. INSULATION ANVIL Figure 1 Figure 2 Place the terminal into the correct die profile until the terminal stopped by the locator. Bring the wire stop blade down; make sure the wire stop located behind the conductor grip. Place a pre-striped wire into the terminal until the end of wire touching the wire stop. See Figure 2. Close the tool until the ratchet releases, the tool handles will then spring open. Carefully remove the crimped terminal. Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 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. The tool was engineered for durability but like any other equipment 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 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. Doc No: ATS-6382522HM Revision: A Release Date: 02-10-12 Revision Date: 02-10-12 UNCONTROLLED COPY Page 3 of 6 Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire) 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 lifting the ratchet release lever. See Figure 6. 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: Repetitive use of this tool should be avoided. 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. Notes: 1. This tool should only be used for the terminals and wire gauges specified on this sheet. 2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above). Variations in tools, terminals, wire stranding and insulation types may affect crimp height. 3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all insulation sizes. 4. Molex does not repair hand tools (see warranty above) The replacement parts listed are the only parts available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased. 5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp testing. 6. Molex does not certify crimp hand tools. CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling. Applications for the Modular Crimp Head WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction and without first reading and understanding the instructions in the proper Manual or Specification Sheet. See Chart below for the correct Manual or Specification Sheet. WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the power by unplugging or turn off the Actuator from its power source. CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury. Doc No: ATS-6382522HM Revision: A Release Date: 02-10-12 Revision Date: 02-10-12 UNCONTROLLED COPY Page 4 of 6 Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire) CAUTION: Wear safety glasses when operating or serving this tool. The chart below shows all applications for this Modular Crimp Head. Modular Crimp Head Order No. 63825-2270 Tool Tool Adapter Adapter Figure Order no. Description Order No. Description No. N/A N/A 3 63816-0000 Hand Crimp Frame (Short) 63816-0050 Hand Crimp Frame (Long) N/A N/A 3 63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 4 63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 4 63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 5 Hand Crimp Tool Applications for the Modular Crimp Head Battery Powered Tool MODULAR CRIMP HEAD LOCKING PINS MODULAR CRIMP HEAD LOCKING PINS HAND CRIMP FRAME LONG OR SHORT Doc No: ATS-6382522HM Revision: A LOCKING PINS AIR POWER CRIMP ADAPTER BATTERY POWERED TOOL LOCKING PINS AIR POWER TOOL Figure 4 Release Date: 02-10-12 Revision Date: 02-10-12 MODULAR CRIMP HEAD BATTERY POWER CRIMP ADAPTER LOCKING PINS Figure 3 Air Powered Tool UNCONTROLLED COPY Figure 5 Page 5 of 6 Hand Crimp Tool for .110 Receptacle Terminals (Magnet Wire) PARTS LIST Hand Crimp Tool 63823-2500 Item Order Number Description Quantity 1 63825-2270 Modular Crimp Head 1 (Ref) 2 63816-0050 Hand Crimp Frame (Long) 1 (Ref) 3 63825-2275 Locator 1 4 63816-0001 Locking Pin 2 5 63600-0525 Handle Spring 1 6 63600-0520 Crimping Spring 2 5 HANDLE SPRING 2 M4 X 14mm LONG BHCS RATCHET RELEASE LEVER 3 4 1 6 CRIMPING SPRING (2) Figure 6 http://www.molex.com Doc No: ATS-6382522HM Revision: A Release Date: 02-10-12 Revision Date: 02-10-12 UNCONTROLLED COPY Page 6 of 6