0638272000

Hand Crimp Tool for.187 Slip on QD Receptacle Terminals HAND CRIMP TOOL Application Tooling Specification Sheet TYPE 4E Order No. 63827-2000 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: .187 Slip on QD Receptacle Terminals, 16-20 AWG UL1015 Wires. Terminal Series No. Terminal Order No. Insulation Diameter Terminal (2) IPC/WHMA-A620 (1) Insulation range AWG mm² mm In. mm In. Wire Size Strip Length mm In. 35718-0800 35718-0810 35718-0900 35718-0910 16-20 NA 2.60-3.20 .102-.126 2.50-3.50 .098-.138 4.40-5.00 .173-.197 35718-1000 35718-1010 Note: This terminal will accommodate the UL1015 Wires. (1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range. (2) Overall insulation OD specification for terminal. (3) Customer to cut off terminal from reel: 0.40mm (.016”) maximum cut-off tab (both ends). 35718 DEFINITION OF TERMS CONDUCTOR CRIMP HEIGHT INSULATION CRIMP WIRE SEAM STRIP LENGTH BELL MOUTH BRUSH CUT-OFF TAB CUT-OFF TAB Doc No: ATS-638272000 Revision: A Release Date: 07-09-15 Revision Date: 07-09-15 UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool for.187 Slip on QD Receptacle Terminals CRIMP SPECIFICATIONS Terminal Series No. 35718 Terminal Series No. Bell mouth mm In. 0.25-0.50 .010-.020 Conductor Brush mm In. 0.50-1.00 .020-.039 Bend up Bend down Twist Roll Degree Max. 3 3 Degree Max. 3 5 35718 Seam Seam shall not be open and no wire allowed out of the crimping area After crimping, the crimp profiles should measure the following: Conductor Crimp Height Width Wire Size Terminal Series No. AWG mm2 35718 16 18 20 NA NA NA Terminal Series No. 35718 Profile A B C 18 AWG 16 AWG 20 AWG 1.45-1.55 .057-.061 2.40-2.60 .094-.102 X 1.30-1.40 .051-.055 2.40-2.60 .094-.102 X 1.20-1.30 .047-.051 2.40-2.60 .094-.102 X mm Wire Size AWG mm2 16 NA 18 NA 20 NA In. mm In. Insulation Crimp Pull Force Minimum Height (Max.) Width (Max.) mm In. mm In. N Lb. 4.00 .157 3.60 .142 127.4 28.7 3.60 .142 3.50 .138 107.8 24.3 3.40 .134 3.40 .134 58.8 13.2 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. CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can occur to the tool or die. 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. Doc No: ATS-638272000 Revision: A Release Date: 07-09-15 Revision Date: 07-09-15 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool for.187 Slip on QD Receptacle Terminals 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. See Figure 1. INSERT TEMINAL Crimping Terminals 1. Select the desired terminal listed in the preceding charts. HANDLES Figure 2 2. Press the wire stop lever to lift up the wire stop. OPEN 3. Load the terminal into the proper nest opening Figure 1 marked with the wire gauge on the hand tool, then lower the wire stop. See Figure 2. 4. Insert the properly stripped wire through the terminal and against the wire stop which is part of the locator. See Figure 3. PRESS TO FLIP UP THE WIRE STOP WIRE STOP WIRE AGAINST THE WIRE STOP TERMINAL PRE-STRIPPED WIRE WIRE Figure 3 TERMINAL 5. Crimp the terminal by squeezing the tool handles until the handles are fully closed. Release the handles to open the jaws. Lift up the wire stop and remove the crimped terminal from the tool. See Figure 4. Note: The tamper proof ratchet action will not release the tool until it has been fully closed 6. Visually inspect the crimped terminal for proper crimp condition. SQUEEZE HANDLES TOGETHER 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. 2. 3. 4. Open the crimp hand tool and turn the tool upside down on the back side. Remove the tightening lock nut. Remove the locator assembly from the frame head. To reinstall the new locator, make sure the hand tool is in the open position. Doc No: ATS-638272000 Revision: A Release Date: 07-09-15 Revision Date: 07-09-15 UNCONTROLLED COPY Figure 4 Page 3 of 7 Hand Crimp Tool for.187 Slip on QD Receptacle Terminals 5. Replace the locator assembly into the frame head. 6. Reinstall the tightening lock nut. MATCH UP MARKS MATCH UP MARKS Remove and Install Tooling 1. 2. 3. 4. 5. Make sure the tool is in open position before remove or install tooling. The locator must be removed before remove or install tooling. Figure 5 Remove the M3 screw which is holding the upper tooling. Remove or install upper tooling through the back side of the tool frame. Install the M3 screw. Make sure the small markings on the front of the hand tool frame match up. See Figure 5. 6. Follow step 3 to 5 for the lower tooling except through the front side of the tool frame and install the M3 screw. Be sure the small markings on the lower tooling line up with upper tooling. 7. Slowly close the tool handles to align upper and lower tooling LUBRICATION together. Tighten the M3 screws and continue squeezing the POINTS tool handles until the hand tool swings open. (BOTH SIDES) 8. Reinstall the locator by following the Instructions in the locator LIGHT OIL (EVERY 3 MONTHS replacement section. OR 1,000 CRIMPS) Maintenance Figure 6 It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: See Figure 6. 1. Un-snap the 2 Snap-On plastic covers front and back. 2. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth. 3. Do not use any abrasive materials that could damage the tool. 4. 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 RATCHET like any other equipment it needs cleaning and lubrication RELEASE LEVER for a maximum service life of trouble free crimping. Light oil (such as 30 weight automotive oil) used at the oil points, every 1,000 crimps or 3 months, will significantly enhance SMALL the tool life. FLAT HEAD 5. Wipe excess oil from hand tool, particularly from crimping SCREWDRIVER area. Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application. 6. When tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping dies, and HANDLES SHOULD BE store the tool in a clean, dry area. PARTIALLY CLOSED Figure 7 Doc No: ATS-638272000 Revision: A Release Date: 07-09-15 Revision Date: 07-09-15 UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool for.187 Slip on QD Receptacle Terminals 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 using a small flat screwdriver pressing up on the ratchet release lever in the movable handle. The handle should be partially closed. See Figure 7. How to Adjust Tool Preload See Figure 8 RATCHET RELEASE LEVER This hand tool is factory preset to 210 N (47 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: RATCHET RELEASE LEVER FLAT HEAD SCREWDRIVER ECCENTRIC AXLE 1. Open the tool by squeezing the handles together until the ratchet mechanism Figure 8 release, the hand tool handles will spring open. SETTING 2. Remove the M3 screw and the M3 washer. WHEEL M3 x 6 LONG 3. Lift the setting wheel off the axle. Use a SCREW WASHER small flat head screwdriver to turn the eccentric axle counter-clockwise (CCW) to increase handle force. 4. To decrease handle force, turn the eccentric axle clockwise (CW). 5. Line up the setting wheel matching the flat side with the flat edge of the axle so the wheel notch will drop onto the roll pin. The numbers will display higher. 6. Re-install the M3 washer and M3 screw. 7. Re-crimp a new sample and check the crimp specifications or conduct a pull test after tool handle preload force is adjusted. 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. Doc No: ATS-638272000 Revision: A Release Date: 07-09-15 Revision Date: 07-09-15 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool for.187 Slip on QD Receptacle Terminals 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-638272000 Revision: A Release Date: 07-09-15 Revision Date: 07-09-15 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for.187 Slip on QD Receptacle Terminals PARTS LIST Item Number REF 1 2 Order Number 63827-2000 63827-2075 63810-0106 Description Hand Crimp Tool Locator Assembly Spring, Ratchet Quantity Figure 9 1 1 2 M4 LOCKNUT 1 M3 x 6 LG SCREW M4 x 30 LG SCREW M4 x 12 LG SCREW Figure 9 Visit our Web site at http://www.molex.com Doc No: ATS-638272000 Revision: A Release Date: 07-09-15 Revision Date: 07-09-15 UNCONTROLLED COPY Page 7 of 7