0638280375

Hand Crimp Tool For 3.96MM (.156”) Pitch KK Crimp Terminals Hand Crimp Tool Application Tooling Specification Sheet TYPE 4A Order No. 63828-0300 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 used 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) This tool is IPC/WHMA-A-620 Class 2 compliant as indicated on page 2 This tool is RoHS compliant SCOPE Products: 3.96mm (.156") Pitch KK Crimp Terminal for 18-22 AWG. Terminal Order No. Wire Size (2) Insulation Diameter Strip Length Loose Piece (1) Reel AWG mm2 mm In. mm In. 08-50-0023 08-58-0136 08-50-0008 08-58-0135 08-50-0706 08-65-0129 08-50-0705 08-65-0128 8818 18-22 N/A 1.57-2.79 .060-.110 2.50-3.00 .098-.118 08-52-0132 08-52-0131 40-01-1181 08-56-0188 08-56-0187 40-01-1182 (1). This hand tool operates best with loose-piece terminals. If reeled terminals are used, customers must cut the terminal from the carrier strip and are responsible for achieving the proper cut-off specification: 2.72 ± 0.08mm (.107 ± .003”). See Figure 1. Terminal Series No. (2). See IPC/WHMA-A-620 conditions on page 2. DEFINITION OF TERMS C/L CONDUCTOR CRIMP CUT-OFF TAB See Note 1 INSULATION CRIMP LOCKING TANG HEIGHT BEND UP BRUSH BELL MOUTH SEAM ROLLING TWISTING CUT-OFF TAB STRIP LENGTH Figure 1 Doc No: 6382803HM Revision: A BEND DOWN CRIMP HEIGHT Release Date: 02-27-18 Revision Date: 02-27-18 UNCONTROLLED COPY C/L Page 1 of 7 Hand Crimp Tool For 3.96MM (.156”) Pitch KK Crimp Terminals OVERLAP FORM GEOMETRY ▲Insulation Crimp Note Due to the terminal’s insulation grip design and/or insulation diameter range, this tool uses the overlap form geometry in the insulation punch. This produces an overlap insulation crimp (A620-compliant). Although 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 CRIMP SPECIFICATIONS Terminal Series No. 8818 Terminal Series No. 8818 WIRE ANVIL Bell Mouth mm In. 0.20-0.50 .008-.020 Bend Up Bend Down Degree Max. 3 3 Conductor Brush mm In. 0.15-0.70 Twist Roll Degree Max. 4 8 .006-.028 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 Insulation Crimp Pull Force ♦♦ Profile Height Width Height (Ref.) Width (Ref.) Minimum Wire Type AWG mm In. mm In. mm In. mm In. N Lb. A B C 18 1.09-1.14 .043-.045 2.53 .099 2.54 .100 110 24.7 X UL1007 20 1.02-1.09 .040-.043 1.85-1.95 .073-.077 2.29 .090 2.43 .096 66 14.8 X 22 0.96-1.02 .038-.040 2.14 .084 2.42 .095 53 11.9 X 8818 18 1.09-1.14 .043-.045 2.69 .106 2.66 .105 110 24.7 X UL1015 20 1.02-1.09 .040-.043 1.85-1.95 .073-.077 2.44 .096 2.49 .098 66 14.8 X 22 0.96-1.02 .038-.040 2.28 .090 2.48 .098 53 11.9 X ♦♦ To achieve IPC-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:  Profile A: 1.80-2.05mm  Profile B: 1.80-2.00mm  Profile C: 1.75-1.85mm Terminal Series No. Wire Tool Qualification Notes 1. (Ref) means the dimension provided is approximate due to the wide range of wires, conductor stranding, insulation diameter and insulation hardness. 2. An occasional pull force test should be performed. It must exceed the minimum pull force specification. 3. Pull force should be measured with no influence from the insulation crimp. To ensure this, strip the wire long enough so the terminal insulation grips do not contact the wire insulation. Doc No: 6382803HM Revision: A Release Date: 02-27-18 Revision Date: 02-27-18 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool For 3.96MM (.156”) Pitch KK Crimp Terminals OPERATION SWING LOCATOR OPEN HAND TOOL OPEN 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 1. With the hand tool in the open position, pivot the terminal locator open by pulling up on the locator knob, and lift the wire stop blade. See Figure 2. 2. Insert the terminal into the correct profile until the terminal is TERMINAL SEATED IN fully seated and stops. LOCATOR 3. Gently pivot the locator closed. 4. Bring down the wire stop blade. 5. Make sure the wire stop blade is fully seated on the terminal behind the conductor grip section. CONDUCTOR PUNCH PUNCH Figure 2 INSULATION PUNCH WIRE STOP BLADE Figure 4 TERMINAL WIRE STOP BLADE WIRE LOCATOR Figure 3 WIRE TERMINAL CONDUCTOR ANVIL INSULATION ANVIL 6. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush toward the tip point on the wire stop blade. See Figure 3. Align the wire so that it is parallel 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 4. 7. Close the tool until the ratchet releases. 8. Lift the wire stop blade. 9. Carefully remove the crimped terminal. Note: To maintain good brush control and a consistent bell mouth, the crimping instructions must be followed. Note: The tamper-proof ratchet action will not release the tool until it has been fully closed. Doc No: 6382803HM Revision: A Release Date: 02-27-18 Revision Date: 02-27-18 UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool For 3.96MM (.156”) Pitch KK Crimp Terminals Terminal Locator Replacement This section describes the procedure for changing the locator. Removal 1. With the tool in the open position, pivot the terminal locator outward. 2. Remove the M4 BHCS. See Figure 5. M4 BHCS Figure 5 CORRECT PIVOT LOCATOR INCORRECT INCORRECT Figure 6 Installation 1. Place the locator on the hand tool. Install the M4 BHCS. See Figure 5. 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 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. 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 a 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 the 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: 6382803HM Revision: A Release Date: 02-27-18 Revision Date: 02-27-18 UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool For 3.96MM (.156”) Pitch KK 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, Molex 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 use 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. 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 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 are damaged or worn, a new tool must be purchased. 5. Pull force should be used as the final criterion 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. Doc No: 6382803HM Revision: A Release Date: 02-27-18 Revision Date: 02-27-18 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool For 3.96MM (.156”) Pitch KK Crimp Terminals 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 plugged 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. The chart below shows all applications for this Modular Crimp Head: Modular Crimp Head Order No. 63828-0370 Tool Tool Adapter Adapter Figure Order No. Description Order No. Description No. 63816-0000 Hand Crimp Frame (Short) N/A N/A 6 63816-0050 Hand Crimp Frame (Long) N/A N/A 6 63816-0200 Battery Power Tool (110 V) 63816-0600 Battery Power Crimp Adapter 7 63816-0250 Battery Power Tool (220 V) 63816-0600 Battery Power Crimp Adapter 7 63816-0100 Air Power Tool 63816-0700 Air Power Crimp Adapter 8 Applications for the Modular Crimp Head Hand Crimp Tool Battery Powered Tool MODULAR CRIMP HEAD LOCKING PINS MODULAR CRIMP HEAD LOCKING PINS BATTERY POWER CRIMP ADAPTER LOCKING PINS HAND CRIMP FRAME LONG OR SHORT Figure 7 Doc No: 6382803HM Revision: A BATTERY POWERED TOOL Air Powered Tool LOCKING PINS AIR POWER CRIMP ADAPTER LOCKING PINS AIR POWER TOOL Figure 8 Release Date: 02-27-18 Revision Date: 02-27-18 MODULAR CRIMP HEAD UNCONTROLLED COPY Figure 9 Page 6 of 7 Hand Crimp Tool For 3.96MM (.156”) Pitch KK Crimp Terminals PARTS LIST Item Order Number Description Quantity 1 63828-0370 Modular Crimp Head 1 2 63816-0000 Hand Crimp Frame (Short) 1 3 63828-0375 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) Application Tooling Support Phone: (402) 458-TOOL (8665) E-Mail: applicationtooling@molex.com Website: www.molex.com/applicationtooling Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed herein belong to their respective owners. Doc No: 6382803HM Revision: A Release Date: 02-27-18 Revision Date: 02-27-18 UNCONTROLLED COPY Page 7 of 7