Hand Crimp Tool For 1.85mm Tab Terminal
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63827-2500
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
Dies and Locator from this tool can be used in the Battery Powered Tool Order No.63816-0200 (110 V) or
63816-0250 (220 V), with the use of the 63816-0800 Crimp Head
Many different tool kits can be used with a single Battery Powered Crimp Tool
This tool is IPC/WHMA A-620 Class 2 compliant
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1.85mm Tab Terminal, Male, 18-20 AWG
Terminal Series No.
35040
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
--35040-9802 18-20 0.82-0.52 2.8 max
.110 max 4.20-5.00 .165-.197
Customer to cut off terminal from reel: 0.2mm (.008”) maximum Cut-off Tab.
See Conditions on page 2.
DEFINITION OF TERMS
BEND UP
STRIP LENGTH
TWISTING
BRUSH
BELL MOUTH
SEAM
BEND DOWN
CUT-OFF
TAB
CONDUCTOR
CRIMP HEIGHT
WIRE
Doc No: ATS-638272500
Revision: A
Release Date: 01-21-14
Revision Date: 01-21-14
INSULATION
CRIMP HEIGHT
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Hand Crimp Tool For 1.85mm Tab Terminal
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
CONDITIONS:
WIRE
ANVIL
After crimping, the conductor profiles should measure the following.
Conductor Crimp
Pull Force Minimum Profile
Width Max (Ref)
AWG mm2
mm
In.
mm
In.
N
Lb.
18 20
18 0.82 1.33-1.40
.052-.055
2.50
.098
107.8
24.3
X
35040
20 0.52 1.25-1.32
.049-.052
2.50
.098
58.8
13.2
X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile 18: 2.50 – 2.00mm (.098-.079 inch)
Profile 20: 2.50 – 1.70mm (.098-.067 inch)
Terminal Series No.
Terminal Series No.
35040
Wire Size
Conductor Crimp Height
Wire Size Insulation Crimp Height Max. (Ref) Insulation Crimp Width Max. (Ref)
AWG mm2
mm
In.
mm
In.
18 0.82
3.80
.150
3.35
.132
20 0.52
3.50
.138
3.35
.132
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.
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.
Doc No: ATS-638272500
Revision: A
Release Date: 01-21-14
Revision Date: 01-21-14
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOGETHER
Figure 2
PUSH ON THE
LOCATOR BUTTON
Figure 1
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Hand Crimp Tool For 1.85mm Tab Terminal
Crimping Terminals
LOCATOR
PUSHED THRU
TOOLING
RELEASE
LOCATOR
BUTTON
TERMINAL
1. Select the desired
terminal listed in the
preceding charts.
2. Make sure the center of
LOCATOR
the locator is in the
BUTTON
down position. With the
PUSHED IN
locator attached, push
the locator button on the
Figure 3
back of the hand tool to
TOOLING
TERMINAL
bring the locator forward
PARTIALLY
through the tooling. See Figure 2.
CLOSED
3. While holding the locator button in, load the terminal into the proper nest
PARTIALLY
opening in the locator based on the wire gauge or terminal type
CLOSE HANDLE
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
OPEN
Figure 4.
POSITION
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
FIRST RATCHET
mechanism cycle has been completed. Release the handles to open
POSITION
the jaws.
WIRE AGAINST
THE WIRE STOP
TERMINAL
WIRE
Figure 4
WIRE STOP IS
PART OF
THE LOCATOR
PRE-STRIPPED
WIRE
Figure 5
TERMINAL
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.
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
WIRE STOP
Figure 6
TERMINAL
Doc No: ATS-638272500
Revision: A
Release Date: 01-21-14
Revision Date: 01-21-14
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Page 3 of 7
Hand Crimp Tool For 1.85mm Tab Terminal
LOCATOR
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.
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
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.
3. Lift and pull away from the hand tool. The
top locator hooks should slip out of the top
slots 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.
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.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
TOP HOOKS
Figure 7B
LOWER TABS
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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:
Figure 8
PUSH ON
HANDLE
1. The locator must be removed before reversing the tooling.
2. Remove the M3 BHCS which is holding the upper
tooling.
MATCH
3. Flip the upper tooling to the opposite side and
UP MARKS
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
Figure 9
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
FRONT
line up.
5. Reinstall the locator by following the Instructions in the locator replacement section.
Doc No: ATS-638272500
Revision: A
Release Date: 01-21-14
Revision Date: 01-21-14
UNCONTROLLED COPY
BACK
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Hand Crimp Tool For 1.85mm Tab Terminal
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
LUBRICATION POINTS
a thin coat of high quality machine oil. Do not oil excessively. The tool
(BOTH SIDES) LIGHT OIL
was engineered for durability but like any other equipment it needs
(EVERY 3 MONTHS OR
cleaning and lubrication for a maximum service life of trouble free
5,000 CRIMPS)
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
Figure 10
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,
RATCHET RELEASE
and store the tool in a clean, dry area.
LEVER
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.
How to Adjust Tool Preload (See Figure 12)
Figure 11
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:
1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link
towards the top of the hand tool
SQUEEZE
frame. This will release the preload
HOLD THE HAND
THE LINK IN
adjustment wheel.
RATCHET
TOOL IN POSITION
THE HANDLE
RELEASE LEVER
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
Figure 12
preload force is adjusted.
SETTING
WHEEL
Doc No: ATS-638272500
Revision: A
Release Date: 01-21-14
Revision Date: 01-21-14
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Hand Crimp Tool For 1.85mm Tab Terminal
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. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. 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-638272500
Revision: A
Release Date: 01-21-14
Revision Date: 01-21-14
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Hand Crimp Tool For 1.85mm Tab Terminal
PARTS LIST
Item Number
REF
1
2
3
Order Number
63827-2500
63827-2575
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
Visit our Web site at http://www.molex.com
Doc No: ATS-638272500
Revision: A
Release Date: 01-21-14
Revision Date: 01-21-14
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