hand crimp tool 1.20mm (.047) pitch pico-ezmate? c rimp terminals doc no: ats-6381948000 release date: 08-17-09 uncontrolled copy page 1 of 6 revision: a revision date: 08-17-09 insulation crimp brush strip length bell mouth crimp height bend down bend up rolling conductor crimp twisting hand crimp tool specification sheet order no. 63819-4800 features % a full cycle ratcheting hand tool ensures complete crimps % this tool is designed to be used with reeled produc t due to the small size of the connector % this tool is designed for prototype work only and i s not designed for production % the reeled product must be cut into 5-inch strips t o be processed in this hand tool % this tool is ipc/whma a-620 class 2 compliant as in dicated % this tool is rohs compliant, however rohs compliant is not required scope products : 1.20mm (.047) pitch pico-ezmate? wire-to-board c rimp terminal, 28 awg. insulation diameter wire size ipc/whma-a620 terminal strip length terminal series no. terminal order no. reel form only awg mm2 mm in. mm in. mm in. 78172-0410 78172 78172-0411 28 0.08 0.55-0.70 .022-.028 0.55-0.70 .022-.028 0.90-1.30 .035-.051 to achieve optimum ipc-a620 insulation crimps, use this insulation od range. overall insulation od specification for terminal. customer to cut off terminal from reel: 0.05mm (.00 2) maximum cut-off tab. 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. type 7
hand crimp tool 1.20mm (.047) pitch pico-ezmate? c rimp terminals doc no: ats-6381948000 release date: 08-17-09 uncontrolled copy page 2 of 6 revision: a revision date: 08-17-09 insulation crimp form this crimp terminal is designed for miniaturization ; therefore, each dimension of insulation crimp por tion appears small as compared to the terminal material thicknes s. in order to avoid insulation piercing the crimp forms by the insulation barrel, coining is provided inside of th e insulation barrel. for this reason, various crim p forms will occur at the tip of the insulation crimp barrel shown in the figure below. these crimp forms maybe changed completely by a sma ll change in the wire, insulation punch, or termina l. these crimp forms are satisfactory for original fun ction of the insulation crimp portion and it is con firmed that all of these forms below are acceptable insulation crimps. conditions: after crimping, the conductor profiles should measu re the following. conductor crimp (ref) insulation crimp (ref) wire size height width height width pull force minimum terminal series no awg mm 2 mm in. mm in. mm in. mm in. n lb. 78172 28 0.08 0.44-0.48 .017-.019 0.85 .033 0.77 .030 0.85 .033 10.0 2.25 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 mechani sm will release the handles, and the hand tool will spring open. crimping terminals 1. select the desired terminal listed in the preceding charts. 2. cut a strip of the terminals approximately 5.0 off the reel. position the terminal strip into the sl ot of the carrier guide with terminals facing forward. 3. push the strip in until it locks into the (2) deten t in the carrier guide and a terminal is centered w ith the punch nest. see figure 1. 4. partially close the jaws of the hand tool by squeez ing the handles until you hear the fist click of th e ratchet. 5. from the top of the hand tool insert the pre-stripp ed wire into the terminal. 6. compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been complet ed. release handles to open the jaws.
hand crimp tool 1.20mm (.047) pitch pico-ezmate? c rimp terminals doc no: ats-6381948000 release date: 08-17-09 uncontrolled copy page 3 of 6 revision: a revision date: 08-17-09 note: the tamper proof ratchet action will not rele ase the tool until it has been fully closed. 7. lift up the crimped terminal from the terminal locator. 8. visually inspect the crimped terminal for proper crimp location. 9. if crimping more wires advance the terminal strip by (1) detent until the terminal is centered with the punch nest. 10. repeat this procedure until all the desired terminals are crimped on the strip. maintenance it is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance steps: 1. remove the plastic handles from the metal tool frame by removing the screws and 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 a thin coat of high qua lity machine oil. do not oil excessively. the tool was engineered for durability but like any fine piece o f equipment it needs cleaning and lubrication for a maximum service life of trouble free crimping. lig ht oil used at the pivot 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. 5. when 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 a rea. miscrimps or jams should this tool ever become stuck or jammed in a p artially closed position, do not force the handles open or closed. the tool will open easily by pressing the ratchet r elease lever up. see figure 2. slide wire into the punch nest figure 1 locks in the terminal strip slide terminal strip into the carrier guide crimp tool open wire ratchet release lever figure 2
hand crimp tool 1.20mm (.047) pitch pico-ezmate? c rimp terminals doc no: ats-6381948000 release date: 08-17-09 uncontrolled copy page 4 of 6 revision: a revision date: 08-17-09 numbered adjustment wheel figure 3 turn clockwise (cw) or counter clockwise (ccw) to adjust the pre-load turn with a small screw driver remove the locking 2mm screw how to adjust tool preload it may be necessary over the life of the tool to ad just tool handle preload force. listed below are t he steps required to adjust the crimping force of the hand t ool to obtain proper crimp conditions: 1. remove the 2mm locking screw from the numbered adju sting wheel using a screw driver. see figure 3. 2. using the same screw driver turn the adjustment whe el to the next highest number. note: the uneven numbers are in clockwise (cw) dir ection and the even numbers are counter clockwise (ccw). 3. example: if the preload is set at number 5, then to increase the preload, turn the adjustment wheel un til the 6 th position is located over the 2mm locking screw tapp ed hole. if it is necessary to move to the 7 th position, then the adjustment wheel should be turned counter clock wise (ccw) until the 7 th position is over the 2mm locking screw tapped hole. 4. replace the 2mm locking screw, aligning the nearest notch in the setting wheel to locking screw. 5. check the crimp specifications and conduct a pull t est after tool handle preload force is adjusted. r epeat these steps until the desired result is obtained. 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.
hand crimp tool 1.20mm (.047) pitch pico-ezmate? c rimp terminals doc no: ats-6381948000 release date: 08-17-09 uncontrolled copy page 5 of 6 revision: a revision date: 08-17-09 cautions: 1. manually powered hand tools are intended for low vo lume, prototyping, or field repair. this tool is not intended for production use. repetitive use of thi s 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 custo mers 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 crimp tool 1.20mm (.047) pitch pico-ezmate? c rimp terminals doc no: ats-6381948000 release date: 08-17-09 uncontrolled copy page 6 of 6 revision: a revision date: 08-17-09 3 figure 4 1 2 4 parts list item order no description quantity ref 63819-4800 hand crimp tool figure 4 1 63819-4870 tool kit 1 2 11-11-0320 spring (ratchet) 1 3 63600-0479 spring (main) 1 4 69008-0972 adjuster wheel 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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