2002188900

Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals Order Number 200218-8900 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 with wire stop holds terminals in the proper crimping position 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 Many different tool kits can be used with a single Battery Powered Crimp Tool This tool is IPC/WHMA-A-620 Class 2 compliant, as indicated on page 2 This tool is RoHS compliant; however, RoHS compliance is not required SCOPE Products: 1.50mm (.059") Pico-SPOX Crimp Terminal, Female, 24-26 AWG, UL1061 Wires. Terminal Series No. Terminal Order No. Wire Size (1) Available in Reel Form Only AWG 24 26 87421 87421-0000 87421-0002 (2) Insulation Diameter Maximum mm In. 1.15 .045 1.00 .039 Strip Length mm In. 1.05-1.54 .041-.061 (1) Customer to cut off terminal from reel: 0.15mm (.006”) maximum cut-off tab. (2) See Conditions on page 2. DEFINITION OF TERMS BELL MOUTH BRUSH BEND UP SEAM ▲INSULATION CRIMP ROLL TWIST BEND DOWN STRIP LENGTH CUT-OFF TAB CONDUCTOR CRIMP CONDUCTOR CRIMP HEIGHT The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope. Doc. No: 2002188900 Revision: A Release Date: 09-21-20 Revision Date: 09-21-20 UNCONTROLLED COPY Page 1 of 7 Hand Crimp Tool for 1.50mm (.059") Pico-SPOX 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. (Some tools with multiple crimp pockets may not have the overlap profile on all pockets.) OVERLAP INSULATION CRIMP CONDITIONS WIRE ANVIL Bell Mouth mm In. Terminal Series No. 87421 0.05-0.30 .002-.012 Conductor Brush mm In. 0.00-0.50 Bend Up Bend Down Twist Roll Degree Degree .000-.020 3 3 3 4 After crimping, the crimp profiles should measure the following: Terminal Series No. 87421 Wire Size AWG 24 26 Conductor Crimp Insulation Crimp Pull Force Height (Ref.) Width (Ref.) Height (Ref.) Width (Ref.) Minimum mm In. mm In. mm In. mm In. N Lb. 0.56-0.60 .022-.024 0.52-0.58 .020-.023 1.00 1.00 .039 .039 1.40 1.24 .055 .049 1.10 1.10 .043 .043 29.4 19.6 6.6 4.4  Profile 24 26 X X To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended: Profile 24: 0.90-1.15mm (.035-.045”) or UL1061 wire Profile 26: 0.80-1.00mm (.032-.040”) or UL1061 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. 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: 2002188900 Revision: A Release Date: 09-21-20 Revision Date: 09-21-20 UNCONTROLLED COPY Page 2 of 7 Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals OPERATION CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects because 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. Crimping Terminals LOCATOR IN DOWN POSTION HANDLE WILL SPRING OPEN 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 forward through the tooling. See Figure 2. 3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the wire gauge or terminal type markings on the hand tool. See Figure 3. SQUEEZE HANDLES TOGETHER Figure 2 Figure 1 RELEASE LOCATOR BUTTON LOCATOR LOCATOR PUSHED THROUGH TOOLING PUSH ON THE LOCATOR BUTTON LOCATOR BUTTON PUSHED IN TERMINAL Figure 3 TERMINAL 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 locator. See Figure 5. 7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed. Release the handles to open the jaws. TERMINAL WIRE AGAINST THE WIRE STOP WIRE STOP IS PART OF THE LOCATOR TOOLING PARTIALLY CLOSED PARTIALLY CLOSE HANDLE OPEN POSITION FIRST RATCHET POSITION Figure 4 PRE-STRIPPED WIRE Figure 5 Doc. No: 2002188900 Revision: A WIRE Release Date: 09-21-20 Revision Date: 09-21-20 TERMINAL UNCONTROLLED COPY Page 3 of 7 Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals 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 Installation 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: 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 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. 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. SQUEEZE HERE SQUEEZE HERE Figure 7A 1. The locator must be removed before reversing the tooling. 2. Remove the M3 BHCS, which is holding the upper tooling. Doc. No: 2002188900 Revision: A Release Date: 09-21-20 Revision Date: 09-21-20 TOP SLOTS OF HAND TOOL TOP HOOKS Figure 7B LOWER TABS JAWS OPEN Right- or Left-Handed Operation This hand tool can be converted from a righthanded 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: MAKE SURE CENTER OF LOCATOR IS IN THE DOWN POSITION PULL OPEN TOOLING TOOLING M3 BHCS Figure 8 PUSH ON HANDLE UNCONTROLLED COPY Page 4 of 7 Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals 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. MATCH UP MARKS Figure 9 BACK FRONT 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. 4. Wipe excess oil from the 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. LUBRICATION POINTS (BOTH SIDES) LIGHT OIL (EVERY 3 MONTHS OR 5,000 CRIMPS) Figure 10 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 Doc. No: 2002188900 Revision: A Release Date: 09-21-20 Revision Date: 09-21-20 UNCONTROLLED COPY Page 5 of 7 Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals How to Adjust Tool Preload (See Figure 12) Hand tool frame preload is factory preset to ensure crimp quality. 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: SQUEEZE THE 1. Open the hand tool. HANDLE CLOSED HOLD THE HAND LINK IN THE 2. Close the handle 2 ratchet clicks. 2 CLICKS TOOL IN POSITION HANDLE 3. 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. 4. Rotate the setting wheel counterclockwise (CCW) to increase handle force. The numbers will display higher. To decrease handle force, rotate the setting wheel Figure 12 clockwise (CW). SETTING WHEEL 5. Release the link to lock the setting wheel in place. 6. 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, 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. 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 website 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: 2002188900 Revision: A Release Date: 09-21-20 Revision Date: 09-21-20 UNCONTROLLED COPY Page 6 of 7 Hand Crimp Tool for 1.50mm (.059") Pico-SPOX Crimp Terminals PARTS LIST Item Number REF 1 2 3 Order Number 200218-8900 200218-8975 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 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: 2002188900 Revision: A Release Date: 09-21-20 Revision Date: 09-21-20 UNCONTROLLED COPY Page 7 of 7