hand tool for disk drive power connection system cr imp terminals doc no: ats-638117000 release date: 01-19-07 uncontrolled copy page 1 of 6 revision: b revision date: 03-29-08 insulation crimp brush strip length bell mouth crimp height bend down bend up rolling conductor crimp twisting type 2c hand crimp tool specification sheet order no. 63811-7000 features a full cycle ratcheting hand tool ensures complete crimps ergonomic soft grip handles for comfortable crimpin g a precision user-friendly terminal locator wire sto p holds terminals in the proper crimping position this tool is ipc/whma-a-620 class 2 and rohs compli ant scope products: disk drive power connection system crimp terminal 1 4-22 awg. terminal order no. wire size insulation diameter st rip length terminal series no. loose piece reel awg mm2 mm in. mm in. 14-16 2.00-1.30 2.75-3.56 .109-.140 4.75-5.54 .187-.218 02-08-1202 02-08-1235 02-08-1237 02-08-1335 02-08-1201 02-08-1234 02-08-1334 02-08-1236 18-20 0.80-0.50 2.00-2.90 .079-.114 4.75-5.54 .187-.218 8980 02-08-1204 02-08-1337 02-08-1203 02-08-1336 18-22 0.80-0.35 1.52-2.30 .060-.090 4.75-5.54 .187-.218 follow the cut-off tab specifications on applicator specification sheets. these terminals cannot be removed from the reel by manual cutting. an applicator must be used or the terminals will no t function properly. definition of terms the above terminal drawing is a generic terminal re presentation. it is not an image of a terminal lis ted in the scope.
hand tool for disk drive power connection system cr imp terminals doc no: ats-638117000 release date: 01-19-07 uncontrolled copy page 2 of 6 revision: b revision date: 03-29-08 conditions: after crimping, the conductor profiles should measu re the following (see notes on page 5). conductor crimp wire size height (ref.) width (ref.) pull force minimum profile terminal series no. awg mm 2 mm in. mm in. n lb. a b c 18 0.80 1.00-1.10 .040-.044 1.92 .076 89.0 20.0 x 20 0.50 1.00-1.10 .040-.044 1.92 .076 71.2 16.0 x 8980 22 0.35 1.00-1.10 .040-.044 1.92 .076 44.5 10.0 x 14 2.00 1.25-1.35 .049-.053 2.32 .091 266.9 60.0 x 16 1.30 1.25-1.35 .049-.053 2.32 .091 133.4 30.0 x 18 0.80 1.20-1.30 .047-.051 2.20 .087 89.0 20.0 x 8980 20 0.50 1.20-1.30 .047-.051 2.20 .087 71.2 16.0 x operation caution: install only molex terminals listed above with this tool. do not crimp hardened objects as damage can occur to the tool or die. open the tool by squeezing the handles together, at the end of the closing stroke, the ratchet mechanism will release the hand les, and the hand tool will spring open. crimping terminals 1. select the desired terminal listed in the preceding charts. 2. swing the terminal locator away from the crimp tool shown in figure 2. some terminals with large insulation grips may inte rfere with the crimp tooling when swinging the locator into position. t he terminal must then be loaded into the locator in the closed/crimp posi tion. 3. when using the locator, press down on the wire stop on the locator as shown in figure 2. insert the p roper terminal into the proper nest opening. make sure w hen choosing the nest opening, it will correspond w ith the a, b, or c profile on the hand tool. 4. return the locator to its original position. insert the proper wire over the terminal. some large o.d . wires may need to be placed into the terminal before closing the tool. gently touch the wire stop with the end of the wire. see figure 3. 5. compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been complet ed. release handles to open the jaws. note: the tamper proof ratchet action will not rele ase the tool until it has been fully closed. 6. remove the crimped terminal from the terminal locat or by pressing down on the wire stop and gently pul ling on the wire. the terminal locator can be in either po sition. 7. visually inspect the crimped terminal for proper cr imp location. figure 1 locator jaws open
hand tool for disk drive power connection system cr imp terminals doc no: ats-638117000 release date: 01-19-07 uncontrolled copy page 3 of 6 revision: b revision date: 03-29-08 note: a crimp height chart is provided with this manual a s reference only. due to the wide range of wires, strands, insulation diameters, and durometers, actual crimp height measurements may ve ry slightly. an occasional, destructive, pull force test should be preformed to check hand tool crimp. pull force value must exceed the minimum pull force specifications listed on page 2. locator replacement see the parts list on the last page of this documen t for the proper locator order number. follow the steps below to replace th e locator. 1. open the crimp hand tool. 2. swing the existing locator open and away from the h and tool. 3. firmly press down on the brass pivot shaft with you r thumb, while pulling the locator up. slip the loca tor off the top of the brass pivot shaft. see figure 4. 4. replace it with the desired locator by putting over the brass pivot shaft and snapping it into place. swing locator open press down on brass pivot shaft lift up locator jaws open figure 4 terminal push here to open wire stop swing open locator locator terminal in place figure 2 locator in place wire stop terminal wire against stop figure 3 wire stop wire
hand tool for disk drive power connection system cr imp terminals doc no: ats-638117000 release date: 01-19-07 uncontrolled copy page 4 of 6 revision: b revision date: 03-29-08 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 sur faces are protected with a thin coat of high quality machine oil. do not oil excessively. the tool was engineered for durab ility but like any fine piece of equipment it needs cleaning and lubrication for a maximum service life of trouble f ree crimping. light oil such as 30 weight automoti ve oil used at the oil points, every 5,000 crimps or 3 months, shown in figure 6 will significantly enhance the to ol life. 4. wipe excess oil from hand tool, particularly from c rimping area. oil transferred from the crimping ar ea onto certain terminations may affect the electrical char acteristics of an application. 5. when tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimpi ng 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 pressing the ratchet release lever. see figure 6. how to adjust tool preload (see figure 6) 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. remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel. 2. remove the locking screw with a 2mm hex wrench. th e wrench set (63810-0101), is not supplied. it is sold separately from the hand tool. 3. turn the eccentric axle and setting wheel with the wrench or pliers counter-clockwise (ccw) to increas e handle force. 4. replace the locking screw, aligning the nearest not ch in the setting wheel to locking screw. 5. replace the handle grip. 6. check the crimp specifications or conduct a pull te st after tool handle preload force is adjusted. ratchet release lever figure 6 handle grip removed eccentric axle handle grip locking screw wrench set (sold seperately) preload check point 25.4mm setting wheel lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 5
hand tool for disk drive power connection system cr imp terminals doc no: ats-638117000 release date: 01-19-07 uncontrolled copy page 5 of 6 revision: b revision date: 03-29-08 warranty this tool is for electrical terminal crimping purpo ses only. this tool is made of the best quality ma terials. all vital components are long life tested. all tools are war ranted to be free of manufacturing defects for a pe riod of 30 days. should such a defect occur, we will repair o r exchange the tool free of charge. this repair or exchange will not be applicable to altered, misused, or damaged t ools. this tool is designed for hand use only. an y clamping, fixturing, or use of handle extensions voids this w arranty. caution : molex crimp specifications are valid only when u sed with molex terminals and tooling. cautions: 1. manually powered hand tools are intended for low vo lume 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 commercial gra de hand tools but rather supplies the following gui delines for customers to re-certify hand tools. % this tool is qualified to pull force only. to re-c ertify, 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 n o faster than 25mm (1.00?) per minute. see the molex web site fo r the quality crimp handbook for more information o n pull testing. % if the tool does not meet minimum pull force values , handle preload should be increased and the pull t est rerun, (see how to adjust preload). % when the hand tool is no longer capable of achievin g minimum pull force, it should be taken out of ser vice and replaced.
hand tool for disk drive power connection system cr imp terminals doc no: ats-638117000 release date: 01-19-07 uncontrolled copy page 6 of 6 revision: b revision date: 03-29-08 ratchet release lever 2 figure 7 m4 x 5lg bhcs 3 4 1 3 parts list item number order number description quantity ref 63811-7000 hand crimp tool figure 7 1 63810-0101 wrench set (not included) 0 2 63810-0102 locator base assembly 1 3 63810-0103 repair kit (not included) 0 4 63811-7075 locator 1 americas headquarters lisle, illinois 60532 u.s.a. 1-800-78molex amerinfo@molex.com far east north headquarters yamato, kanagawa, japan 81-462-65-2324 feninfo@molex.com far east south headquarters jurong, singapore 65-6-268-6868 fesinfo@molex.com european headquarters munich, germany 49-89-413092-0 eurinfo@molex.com corporate headquarters 2222 wellington ct. lisle, il 60532 u.s.a. 630-969-4550 fax: 630-969-1352 visit our web site at http://www.molex.com
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