2002185175

Hand Crimp Tool for Spot-On Crimp Terminals Order Number 200218-5100 Application Tooling Specification TYPE 4D FEATURES       A full cycle ratcheting hand tool ensures complete crimps Ergonomic soft grip handles for comfortable crimping A precision user-friendly terminal locator holds terminals in the proper crimping position Right- or left-handed operation Dies and locator from this tool can be used in the Battery Powered Tool Order No. 63816-0270 (110 V) or 63816-0280 (220 V), with the use of the 63816-0800 Crimp Head This tool is IPC/WHMA-A-620 Class 2 compliant, as indicated below SCOPE Products: Spot-On Crimp Terminals, 24-28 AWG. Terminal Terminal Order Series No. No. 201649 201649-5000 Wire Wire Type Size UL1061 24 AWG UL1061 26 AWG UL1061 28 AWG Insulation Diameter IPC/WHMA-A-620 (1) Terminal (2) mm In. mm In. 1.00-1.15 .039-.045 1.12 .044 0.95-1.15 .037-.045 0.99 .039 0.85-1.00 .033-.039 0.86 .034 Strip Length mm In. 1.50-1.90 .059-.075 (1) To achieve optimum IPC/WHMA-A-620 Class 2 insulation crimps, use this insulation OD. (2) Overall insulation OD specification for terminal. DEFINITION OF TERMS INSULATION CRIMP SEAM STRIP LENGTH CONDUCTOR BRUSH BELL MOUTH BEND UP ROLL TWIST CONDUCTOR CRIMP BEND DOWN Doc No: 2002185100 Revision: A Release Date: 11-04-19 Revision Date: 11-04-19 UNCONTROLLED COPY CUT-OFF TAB Page 1 of 7 Hand Crimp Tool for Spot-On Crimp Terminals ▲ Insulation Crimp Note OVERLAP FORM GEOMETRY PUNCH Due to the terminal’s insulation grip design or insulation diameter range, this tool uses overlap form geometry in the insulation punch. This produces an overlap insulation crimp (A-620compliant). Although the insulation punch profile may appear lopsided, this is a normal condition for this tool. See figure to the right. This tool uses the overlap form on all crimp profiles. OVERLAP INSULATION CRIMP CONDITIONS WIRE ANVIL After crimping, the crimp profiles should measure the following: Bell Mouth Terminal Series No. 201649 mm 0.10-0.40 .004-.016 Terminal Series No. 201649 mm In. 0.60 .024 Bend Up Bend Down Twist Degree 3 2 Height 3 6 Profile Width (Ref) Wire Type Wire Size mm In. mm In. 24 UL1061 UL1061 UL1061 24 AWG 26 AWG 28 AWG 0.54-0.59 0.48-0.53 0.44-0.49 .021-.023 .019-.021 .017-.019 1.00-1.10 1.00-1.10 1.00-1.10 .039-.043 .039-.043 .039-.043 X Wire Size Insulation Crimp Height (Ref) Roll Degree Conductor Crimp Wire Terminal Series No. 201649 Conductor Brush In. Width (Ref) 26 28 X X Pull Force Minimum Wire Type Wire Size mm In. mm In. N Lb. UL1061 UL1061 UL1061 24 AWG 26 AWG 28 AWG 1.50-1.60 1.45-1.55 1.35-1.45 .059-.063 .057-.061 .053-.057 1.05-1.20 1.05-1.20 1.05-1.20 .041-.047 .041-.047 .041-.047 29.4 19.6 9.8 6.6 4.4 2.2 Tool Qualification Notes 1. (Ref) means that the dimension provided is approximate because of the wide range of wires, conductor stranding, insulation diameter and insulation hardness. 2. An occasional conductor crimp height measurement should be performed. It must lie between the minimum and maximum crimp height 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. Notes 1. This tool should only be used for the terminals and wire gauges specified on this sheet. 2. Variations in tools, terminals, wire stranding and insulation types may affect crimp height. 3. This tool is intended for AWG conductor sizes. It may not give good insulation crimp support for insulation sizes outside of the specified range. 4. Molex does not repair hand tools. See warranty on page 6. The replacement parts listed are the only parts available for repair. If the handles or crimp tooling become damaged or worn, a new tool must be purchased. 5. Conductor crimp height should be used as the final criterion for an acceptable crimp. Refer to Molex Quality Crimping Handbook 63800-0029 for additional information on crimping and crimp testing. 6. Molex does not certify hand crimp tools. Doc No: 2002185100 Revision: A Release Date: 11-04-19 Revision Date: 11-04-19 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool for Spot-On Crimp Terminals ▲ Note The crimp height chart is provided with this document as reference only. Due to the wide range of wires, strands, insulation diameters and insulation hardness available, actual crimp height measurements may vary slightly. An occasional destructive pull force test should be performed to verify the conductor crimp. The 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 or crimp dies. 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 HANDLE WILL SPRING OPEN 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 SQUEEZE forward through the tooling. See Figure 2. HANDLES 3. While holding the locator button in, load TOGETHER the terminal into the proper nest opening Figure 1 in the locator based on the wire gauge or terminal type markings on the hand tooling. See Figure 3. LOCATOR PUSHED THROUGH TOOLING Figure 2 PUSH ON THE LOCATOR BUTTON RELEASE LOCATOR BUTTON LOCATOR LOCATOR BUTTON PUSHED IN TERMINAL Doc No: 2002185100 Revision: A Figure 3 Release Date: 11-04-19 Revision Date: 11-04-19 TERMINAL UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool for Spot-On Crimp Terminals TOOLING PARTIALLY CLOSED 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 Figure 4. 6. Insert the properly stripped wire through the terminal and against the wire stop. See Figure 5. WIRE AGAINST THE WIRE STOP PARTIALLY CLOSE HANDLE WIRE STOP IS PART OF THE LOCATOR OPEN POSITION TERMINAL PRE-STRIPPED WIRE FIRST RATCHET POSITION Figure 4 Figure 5 WIRE TERMINAL 7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release the handles to open the jaws. Note: The tamper-proof ratchet action will not release the tool until it has been fully closed. WIRE 8. Remove the crimped terminal from the terminal locator by pulling on the wire. 9. Visually inspect the crimped terminal for proper crimp location. 10. 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, and then close the tool. See Figure 6. WIRE STOP TERMINAL Figure 6 Locator Replacement LOCATOR 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 hand crimp 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 center of the locator down as far as it will go as shown in Figure 7B. SQUEEZE HERE SQUEEZE HERE MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION Figure 7A TOP SLOTS OF HAND TOOL TOP HOOKS Figure 7B LOWER TABS Doc No: 2002185100 Revision: A Release Date: 11-04-19 Revision Date: 11-04-19 UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool for Spot-On Crimp Terminals 6. Holding onto the lower part of the locator with your thumb and index finger, insert the locator’s top hooks into the hand tool’s 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. Right- or Left-Handed 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 Figures 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. JAWS OPEN PULL OPEN TOOLING TOOLING M3 BHCS Figure 8 PUSH ON HANDLE MATCH UP MARKS Figure 9 FRONT BACK 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. See Figure 10. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) Figure 10 Doc No: 2002185100 Revision: A Release Date: 11-04-19 Revision Date: 11-04-19 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool for Spot-On Crimp Terminals 4. Wipe excess oil from the hand tool, particularly from the 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. RATCHET RELEASE 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. Figure 11 How to Adjust Tool Preload (See Figure 12) This hand tool is factory preset to 25-45 pounds 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 12. Using your index finger, squeeze the link toward 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, 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: Molex crimp specifications are valid only when used with Molex terminals and tooling. 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. Doc No: 2002185100 Revision: A Release Date: 11-04-19 Revision Date: 11-04-19 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for Spot-On Crimp Terminals PARTS LIST Item Number REF 1 2 3 Order Number 200218-5100 200218-5175 63810-0104 63810-0106 Description Hand Crimp Tool Locator Assembly Spring, Return Spring, Ratchet Quantity Figure 13 1 1 1 2 1 RATCHET RELEASE LEVER 3 Figure 13 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: 2002185100 Revision: A Release Date: 11-04-19 Revision Date: 11-04-19 UNCONTROLLED COPY Page 7 of 7