0638257600

Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals HAND CRIMP TOOL Application Tooling Specification Sheet TYPE 4D Order No. 63825-7600 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 as indicated This tool is RoHS compliant, however RoHS compliant is not required SCOPE Products: 2.28mm (.090”) Receptacle Terminal with Seal, 0.30-0.50mm² AVSS. Wire Size Insulation Diameter Strip Length AWG mm² mm In. mm In. 35407 35407-6302 35407-6702 N/A 0.30-0.50 1.40-2.10 .055-.083 5.00-5.60 .197-.220 This Hand Tool provides optimum A-620 Class 2 crimps with insulation O.D. range of 1.40-2.10 mm. Terminal Series No. Terminal Order No. DEFINITION OF TERMS BEND UP TWISTING TRIP LENGTH CONDUCTOR BRUSH BELL MOUTH SEAM ROLLING BEND DOWN WIRE CUT-OFF TAB CONDUCTOR CRIMP HEIGHT INSULATION CRIMP HEIGHT SEAL Doc No: ATS-638257600 Revision: A Release Date: 08-12-13 Revision Date: 08-12-13 UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals CRIMP SPECIFICATION Bell mouth Mm In. 0.3-0.6 .011-.023 Terminal Series No. 35407 Terminal Series No. Cut-off Tab Maximum mm In. 0.0-0.30 .011 Bend up Bend down Twist Degree 35407 3 Roll Degree 3 5 3 Conductor Brush mm In. 0.30 – 0.80 .011-.031 Punch Width mm (Ref) Seam Conductor Insulation Seam shall not be open mm In mm In and no wire allowed out of the crimping area 1.80 .071 3.80 .150 After crimping, the conductor profiles should measure the following (See notes). Terminal Series No. Type AVS AVSS AVS AVSS 35407 Terminal Series No. 35407 Conductor Insulation Crimp Height Crimp Width (Ref) Crimp Height Crimp Width mm2 mm In. mm In. mm In. mm In. 0.50 1.01-1.12 .039-.044 1.80 .071 N/A N/A 3.80 .150 0.50 1.01-1.12 .039-.044 1.80 .071 N/A N/A 3.80 .150 0.30 0.89-1.01 .035-.039 1.80 .071 N/A N/A 3.80 .150 0.30 0.89-1.01 .035-.039 1.80 .071 N/A N/A 3.80 .150 Wire Size Wire Size Pull Force Minimum AWG mm2 N/A 0.50 N/A 0.30 N 88.3 58.8 Lb 65.1 43.3 Single Wire Seal Profile 0.3mm2 0.5mm2 X 35903-0022 (M) (Black) X 0.70mm (REF) SEAL POSTION Cable Seal Position On a Wire (Before crimping) WIRE INSULATION SEAL 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: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as damage can occur to the tool frame and/or crimp dies. Doc No: ATS-638257600 Revision: A Release Date: 08-12-13 Revision Date: 08-12-13 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals 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. LOCATOR IN DOWN POSTION 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. 3. While holding the locator button in, load the terminal with the seal into the proper nest opening in the locator based on the wire gauge or terminal type markings on the hand tooling. See Figure 3. LOCATOR PUSHED THRU TOOLING HANDLE WILL SPRING OPEN SQUEEZE HANDLES TOGETHER Figure 2 PUSH ON THE LOCATOR BUTTON RELEASE LOCATOR BUTTON Figure 1 TERMINAL LOCATOR BUTTON PUSHED IN Figure 3 TERMINAL 4. Release the locator button, allowing the locator to return to the crimping position. 5. With the hand tool open, insert the properly stripped wire and seal under the punches into the lower part of the upper tooling, until the wire is against the wire stop. See Figure 4. 6. Seal position should be under and inside the punches, keep this position while crimping. 7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release the handles to open the jaws. WIRE AGAINST THE WIRE STOP WIRE STOP IS PART OF THE LOCATOR WIRE AND SEAL POSITIONED IN LOWER PART OF THE PUNCHES WIRE AND SEAL POSITON TERMINAL Doc No: ATS-638257600 Revision: A Release Date: 08-12-13 Revision Date: 08-12-13 Figure 4 TERMINAL UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals Note: The tamper proof ratchet action will not release the tool until it has been fully closed. 8. Remove the crimped terminal from the terminal locator by pulling on the wire. 9. Visually inspect the crimped terminal for proper crimp location. 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. Squeeze gently on the lower area shown in Figure 7A with your thumb and index finger. The lower tabs of the locator should disengage from the hand tool. LOCATOR SQUEEZE HERE SQUEEZE HERE Figure 7A JAWS OPEN MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION PULL OPEN TOOLING TOOLING M3 BHCS TOP SLOTS OF HANDTOOL TOP HOOKS Figure 8 Figure 7B PUSH ON HANDLE LOWER TABS MATCH 3. Lift and pull away from the hand tool. The top locator UP MARKS hooks should slip out of the top slots easily. See Figure 7A. 4. To reinstall the new locator, make sure the hand tool Figure 8 is in the open position. 5. Press the red insert down as far as it will go as shown in Figure 7B. BACK FRONT 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. 7. Rotate the locator down and press the lower tabs into the two bottom slots of the hand tool. To secure the locator into place, the lower tabs must snap into place on the hand tool frame. Doc No: ATS-638257600 Revision: A Release Date: 08-12-13 Revision Date: 08-12-13 UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals Right or Left Hand Operation 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. 2. Remove the M3 BHCS which is holding the upper tooling. 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, 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 the M3 screws. Be sure the small markings line up. 5. Reinstall the locator by following the Instructions in the locator replacement section. Maintenance It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) 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 Figure 10 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 RATCHET RELEASE application. LEVER 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. Figure 11 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: Doc No: ATS-638257600 Revision: A Release Date: 08-12-13 Revision Date: 08-12-13 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals 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-638257600 Revision: A Release Date: 08-12-13 Revision Date: 08-12-13 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for 2.28mm (.090”) Sealed Receptacle Terminals PARTS LIST Item Number REF 1 2 3 Order Number 63825-7600 63825-7675 63810-0104 63810-0105 Description Hand Crimp Tool Locator Assembly Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 2 1 RATCHET RELEASE LEVER Figure 13 3 Visit our Web site at http://www.molex.com Doc No: ATS-638257600 Revision: A Release Date: 08-12-13 Revision Date: 08-12-13 UNCONTROLLED COPY Page 7 of 7