0638258870

Hand Crimp Tool For SL™ Crimp Terminals Modular Crimp Head Order No. 63825-8870 Application Tooling Specification Sheet TYPE 4A Hand Crimp Tool Order No. 63825-8800 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 A-620 Class 2 compliant as indicated and RoHS compliant 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: SL™ Crimp Terminals, 24-30 AWG. Terminal Series No. 50083 50087 70021 70058 71851 Terminal Order No. Wire Size ●Insulation Diameter Strip Length Loose Piece Reel AWG mm² mm In. mm In. 50083-8100 50083-8160 50083-8000 50083-8060 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125 50083-8114 50083-8170 50083-8114 50083-8070 50087-8100 50087-8130 50087-8000 50087-8060 50087-8114 50087-8160 50087-8014 50087-8099 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125 50087-8030 16-02-0108 40-08-0872 16-02-0077 16-02-0105 16-02-0109 16-02-0078 40-08-0871 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125 16-02-0110 16-02-0091 16-02-0096 70058-0096 16-02-0069 16-02-0150 16-02-0097 70058-0097 16-02-0082 70058-0069 16-02-0098 70058-4096 16-02-0083 70058-0082 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125 16-02-0140 16-02-0137 70058-0083 16-02-0151 16-02-0139 70058-4069 16-02-1109 16-02-0117 16-02-1112 16-02-0119 24-30 0.20-0.05 1.01-1.52 .040-.060 2.54-3.17 .100-.125 16-02-1116 16-02-1117 16-02-1113 71851-0119 For customer to cut off terminal from reel, see crimp specifications for desired terminal series. Doc No: ATS-6382588HM Revision: A Release Date: 09-09-13 Revision Date: 09-09-13 UNCONTROLLED COPY Page 1 of 8 Hand Crimp Tool For SL™ Crimp Terminals DEFINITION OF TERMS BEND UP BELL MOUTH BRUSH INSULATION CRIMP ▲SEE NOTE SEAM ROLLING TWISTING STRIP LENGTH BEND DOWN CUT-OFF TAB CONDUCTOR COND.CRIMP 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 GEOMETRY PUNCH ▲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 INSULATION CRIMP CRIMP SPECIFICATIONS: Bell mouth Terminal Series No. mm 0.20-0.50 0.20-0.50 0.20-0.50 0.20-0.50 0.20-0.50 50083 50087 70021 70058 71851 Terminal Series No. 50083 50087 70021 70058 71851 Doc No: ATS-6382588HM Revision: A WIRE ANVIL In. .008-.020 .008-.020 .008-.020 .008-.020 .008-.020 Cut-off Tab Maximum Front Rear mm In. mm In. 0.15 .006 0.30 .012 0.15 .006 0.30 .012 0.13 .005 0.13 .005 0.13 .005 0.08 .003 0.13 .005 0.08 .003 Bend up Bend down Degree 3 3 3 3 3 3 3 3 3 3 Release Date: 09-09-13 Revision Date: 09-09-13 Twist Roll Degree 3 8 3 8 3 8 3 8 3 8 Conductor Brush mm 0.00-1.00 0.00-1.00 0.00-1.00 0.00-1.00 0.00-1.00 In. .000-.039 .000-.039 .000-.039 .000-.039 .000-.039 Seam Seam shall not be open and no wire allowed out of the crimping area UNCONTROLLED COPY Page 2 of 8 Hand Crimp Tool For SL™ Crimp Terminals After crimping, the conductor profiles should measure the following. Conductor Crimp Insulation Crimp Pull Force Profile Height Width (Ref.) Height (Ref.) Width (Ref.) Minimum AWG mm2 mm In. mm In. mm In. mm In. N Lb. 24 26 28 30 24 0.20 0.79-0.87 .031-.034 1.05 .041 1.60 .063 1.60 .063 29.4 6.61 X 26 0.12 0.74-0.81 .029-.032 1.05 .041 1.58 .062 1.58 .062 19.6 4.41 X 50083 28 0.08 0-71-0.78 .028-.031 1.05 .041 1.55 .061 1.58 .062 9.8 2.20 X 30 0.05 0-67-0.74 .026-.029 1.05 .041 1.55 .061 1.57 .062 4.9 1.10 X 24 0.20 0.79-0.87 .031-.034 1.05 .041 1.60 .063 1.60 .063 29.4 6.61 X 26 0.12 0.74-0.81 .029-.032 1.05 .041 1.58 .062 1.58 .062 19.6 4.41 X 50087 28 0.08 0-71-0.78 .028-.031 1.05 .041 1.55 .061 1.58 .062 9.8 2.20 X 30 0.05 0-67-0.74 .026-.029 1.05 .041 1.55 .061 1.57 .062 4.9 1.10 X 24 0.20 0.79-0.84 .031-.033 1.05 .041 1.60 .063 1.60 .063 28.9 6.50 X 26 0.12 0.74-0.79 .029-.031 1.05 .041 1.58 .062 1.58 .062 17.8 4.00 X 70021 28 0.08 0-71-0.76 .028-.030 1.05 .041 1.55 .061 1.58 .062 11.1 2.50 X 30 0.05 0-66-0.71 .026-.028 1.05 .041 1.55 .061 1.57 .062 6.7 1.50 X 24 0.20 0.79-0.84 .031-.033 1.05 .041 1.60 .063 1.60 .063 28.9 6.50 X 26 0.12 0.74-0.79 .029-.031 1.05 .041 1.58 .062 1.58 .062 17.8 4.00 X 70058 28 0.08 0-71-0.76 .028-.030 1.05 .041 1.55 .061 1.58 .062 11.1 2.50 X 30 0.05 0-66-0.71 .026-.028 1.05 .041 1.55 .061 1.57 .062 6.7 1.50 X 24 0.20 0.79-0.84 .031-.033 1.05 .041 1.60 .063 1.60 .063 28.9 6.50 X 26 0.12 0.74-0.79 .029-.031 1.05 .041 1.58 .062 1.58 .062 17.8 4.00 X 71851 28 0.08 0-71-0.76 .028-.030 1.05 .041 1.55 .061 1.58 .062 11.1 2.50 X 30 0.05 0-66-0.71 .026-.028 1.05 .041 1.55 .061 1.57 .062 6.7 1.50 X ●To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended: Profile 24: 1.25-1.40mm (.049-.055 inch) Profile 26: 1.15-1.35mm (.045-.053 inch) Profile 28: 1.10-1.30mm (.043-.051 inch) Profile 30: 1.10-1.25mm (.043-.049 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. 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. 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. 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. Doc No: ATS-6382588HM Revision: A Release Date: 09-09-13 Revision Date: 09-09-13 UNCONTROLLED COPY Page 3 of 8 Hand Crimp Tool For SL™ Crimp Terminals 1. With the hand tool in the open position, pivot the terminal locator open by pulling on the locator knob and lift the wire SWING HAND stop blade up. See Figure 1. LOCATOR OPEN TOOL 2. Insert the terminal into the correct profile until the terminal OPEN is fully seated and stops. Make sure the wire stop blade is fully in up position. WIRE 3. Gently pivot the locator closed. STOP BLADE 4. Bring down the wire stop blade. Make sure the wire stop blade is fully seated on the terminal behind the conductor grip section. TERMINAL 5. Slide the pre-stripped wire into the terminal; make sure to SEATED IN aim the wire brush towards the tip point on the wire stop LOCATOR blade. See Figure 2. Align the wire so that it is parallel Figure 1 and sitting into the terminal. Maintain a light and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the wire.) Be sure to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3. CONDUCTOR PUNCH WIRE STOP BLADE WIRE STOP BLADE TERMINAL INSULATION PUNCH INSULATION PUNCH LOCATOR WIRE TERMINAL WIRE CONDUCTOR ANVIL Figure 2 Figure 3 INSULATION ANVIL 6. Close the tool until the ratchet releases, the tool handles will then spring open. 7. Lift the wire stop blade up. 8. Carefully remove the crimped terminal. Pivot the terminal locator slightly out if necessary. See Figure 4. Note: The tamper proof ratchet action will not release the tool until it has been fully closed. REMOVE CRIMPED WIRE Figure 4 Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed. Doc No: ATS-6382588HM Revision: A Release Date: 09-09-13 Revision Date: 09-09-13 UNCONTROLLED COPY PIVOT LOCATOR Page 4 of 8 Hand Crimp Tool For SL™ Crimp Terminals Terminal Locator Replacement/Change Over This section describes the procedure for changing locators. Removal 1. With the tool in the open position, pivot the terminal locator outward. 2. Remove the M4 BHCS. See Figure 4. M4 BHCS Installation PIVOT 1. Place the replacement locator on the hand tool. Install the M4 BHCS. See LOCATOR Figure 5 Figure 6. 2. Tighten the screw enough to hold the locator. Make sure the locator can still float freely with hand pressure. 3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then gently pivot the locator closed. 4. With hand pressure, slowly slide the locator to the correct position. See Figure 6. 5. Gently pivot the locator open without disturbing the location. 6. Hold the locator firmly in place and slowly tighten the M4 BHCS. CORRECT INCORRECT Maintenance INCORRECT Figure 6 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. 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 10. Doc No: ATS-6382588HM Revision: A Release Date: 09-09-13 Revision Date: 09-09-13 UNCONTROLLED COPY Page 5 of 8 Hand Crimp Tool For SL™ 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: 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. 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. CAUTION: Wear safety glasses when operating or serving this tool. Doc No: ATS-6382588HM Revision: A Release Date: 09-09-13 Revision Date: 09-09-13 UNCONTROLLED COPY Page 6 of 8 Hand Crimp Tool For SL™ Crimp Terminals The chart below shows all applications for this Modular Crimp Head. Modular Crimp Head Order No. 63825-8870 Tool Tool Adapter Adapter Figure Order no. Description Order No. Description No. 63816-0000 Hand Crimp Frame (Short) N/A N/A 7 63816-0050 Hand Crimp Frame (Long) N/A N/A 7 63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 8 63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 8 63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 9 Applications for the Modular Crimp Head Hand Crimp Tool Battery Powered Tool MODULAR CRIMP HEAD LOCKING PINS MODULAR CRIMP HEAD LOCKING PINS HAND CRIMP FRAME LONG OR SHORT Doc No: ATS-6382588HM Revision: A LOCKING PINS AIR POWER CRIMP ADAPTER BATTERY POWERED TOOL LOCKING PINS AIR POWER TOOL Figure 8 Release Date: 09-09-13 Revision Date: 09-09-13 MODULAR CRIMP HEAD BATTERY POWER CRIMP ADAPTER LOCKING PINS Figure 7 Air Powered Tool UNCONTROLLED COPY Figure 9 Page 7 of 8 Hand Crimp Tool For SL™ Crimp Terminals PARTS LIST Item Order Number Description Quantity 1 63825-8870 Modular Crimp Head 1 2 63816-0000 Hand Crimp Frame (Short) 1 3 63825-8875 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 8mm LONG BHCS RATCHET RELEASE LEVER 3 LOCATOR Figure 10 4 1 6 CRIMPING SPRING (2) Visit our Web site at http://www.molex.com Doc No: ATS-6382588HM Revision: A Release Date: 09-09-13 Revision Date: 09-09-13 UNCONTROLLED COPY Page 8 of 8