handcrimptoolfor 1. 80mm(.071 ) pcboardcrimpterminal docno:ats638237100 releasedate:030111 uncontrolled copy page1of7 revision:a revisiondate:030111 conductor brush strip length seam conductor crimp height cut-off tab bell mouth bend up twisting rolling bend down wire insulation crimp hand crimp tool application tooling specification sheet order no. 63823-7100 features afullcycleratchetinghandtoolensurescomplete crimps ergonomicsoftgriphandlesforcomfortablecrimpin g aprecisionuserfriendlyterminallocatorwiresto pholdsterminalsinthepropercrimpingposition rightandlefthandedapplications thistoolisipc/whmaa620class2compliant thistoolisrohscompliant,howeverrohscompliant isnotrequired scope products :1.80mm(.071)pcboardcrimpterminal,1822awg . terminal series no. terminal order no. wire size insulation diameter strip length reel awg mm2 mm in. mm in. 35740 357401410 1822 0.800.35 1.703.00 .067.118 4.24.8 .165.189 customertocutoffterminalfromreel:0.20mm(.00 8)maximumcutofftab. definition of terms type 4d
handcrimptoolfor 1. 80mm(.071 ) pcboardcrimpterminal docno:ats638237100 releasedate:030111 uncontrolled copy page2of7 revision:a revisiondate:030111 insulation crimp note : duetotheterminalsinsulationgripdesign and/orinsulationdiameterrange,thistool usesoverlapformgeometryinthe insulationpunch.thisproducesanoverlap insulationcrimp(a620Ccompliant).while theinsulationpunchprofilemayappear lopsided,thisisanormalconditionforthis tool.seefiguretotheright.(sometoolswith multiplecrimppocketsmaynothavethe overlapprofileonallpockets). conditions: aftercrimping,theconductorprofilesshouldmeasu rethefollowing. terminal series no wire size conductor crimp insulation crimp pull force minimum profile height (ref.) width (ref.) height (ref.) width (ref.) awg mm 2 mm in. mm in. mm in. mm in. n lb. 18 20 22 35740 18 0.80 1.251.35 .049.053 2.2 .086 3.40 .134 3.05 .120 88.26 19.84 x 20 0.50 1.151.25 .045.049 2.2 .086 3.30 .130 3.00 .118 58.84 13.23 x 22 0.35 1.051.15 .041.045 2.2 .086 2.95 .116 2.90 .114 39.23 8.82 x tool qualification notes: 1. pullforceshouldbemeasuredwithno influencefromtheinsulationcrimp. 2. theabovespecificationsareguidelinesto anoptimumcrimp note: acrimpheightchartisprovidedwiththis manualasreferenceonly. duetothewide rangeofwires,strands,insulationdiameters, anddurometersavailable,actualcrimpheight measurementsmayvaryslightly.an occasional,destructive,pullforcetestshouldbe performedtocheckhandtoolcrimp.pullforce valuemust exceedtheminimumpullforce specificationslisted. operation caution: installonlymolexterminalslistedabovewiththis tool.donotcrimphardenedobjectsasdamage canoccurtothetoolordie. openthetoolbysqueezingthehandlestogether.a ttheendoftheclosingstroke,theratchetmechan ismwill releasethehandlesandthehandtoolwillspringo pen.seefigure1. locator in down postion push on the locator button figure 2 squeeze handles together handle will spring open figure 1 make sure center of locator overlap form geometry anvil punch wire
handcrimptoolfor 1. 80mm(.071 ) pcboardcrimpterminal docno:ats638237100 releasedate:030111 uncontrolled copy page3of7 revision:a revisiondate:030111 release locator button terminal figure 3 locator pushed thru tooling terminal locator button pushed in locator figure 5 terminal wire against the wire stop wire wire stop is part of the locator pre-stripped wire terminal crimping terminals 1. selectthedesiredterminallistedinthepreceding charts. 2. makesurethecenterofthelocatorisinthedown position.withthe locatorattached,pushthelocatorbuttonontheba ckofthehandtoolto bringthelocatorforwardthroughthetooling.see figure2. 3. whileholdingthelocatorbuttonin,loadthetermi nalintothepropernest openinginthelocatorbasedonthewiregaugeort erminaltype markingsonthehandtooling.seefigure3. 4. releasethelocatorbutton,allowingthelocatorto returntothecrimping position. 5. closethetoolhandleuntilthefirstratchetposit ionengages.seefigure 4. 6. inserttheproperlystrippedwirethroughthetermi nalandagainstthe wirestop.seefigure5. 7. crimptheterminalbysqueezingthetoolhandlesun tiltheratchet mechanismcyclehasbeencompleted.releasetheha ndlestoopenthejaws. note:thetamperproofratchetactionwillnotrele asethetooluntilithasbeenfullyclosed. partially close handle tooling partially closed figure 4 first ratchet position open position
handcrimptoolfor 1. 80mm(.071 ) pcboardcrimpterminal docno:ats638237100 releasedate:030111 uncontrolled copy page4of7 revision:a revisiondate:030111 figure 8 push on handle jaws open pull open tooling tooling m3 bhcs 8. removethecrimpedterminalfromtheterminal locatorbypullingonthewire. 9. visuallyinspectthecrimpedterminalforpropercr imp location. 10. onsomelargeo.d.wires,itmaynotbepossibleto insertthewirewiththetoolpartiallyclosed.th ose wiresshouldbeinsertedwiththehandtoolinthe openposition.insertthewireabovetheterminal in thepunchandagainstthewirestopthenclosethe tool.seefigure6. locator replacement seethepartslistonthelastpageofthisdocumen tfor theproperlocatorordernumber.followthesteps belowtoreplacethelocator. 1. openthecrimphandtool. 2. squeezegentlyonthelowerareashownin figure7awithyourthumbandindexfinger.the lowertabsofthelocatorshoulddisengagefrom thehandtool. 3. liftandpullawayfromthehandtool.thetop locatorhooksshouldslipoutofthetopslots easily.seefigure7a. 4. toreinstallthenewlocator,makesurethehand toolisintheopenposition. 5. presstheredinsertdownasfarasitwillgoas showninfigure7b. 6. holdingontothelowerpartofthelocatorwith yourthumbandindexfinger,insertthelocators tophooks(2)intothehandtooltopslots. 7. rotatethelocatordownandpressthelowertabs intothetwobottomslotsofthehandtool.to securethelocatorintoplace,thelowertabsmust snapintoplaceonthehandtoolframe. right or left hand operation thishandtoolhasanaddedfeaturethatcanbe convertedfromarighthandedapplicationtoaleft handedapplication.itisnecessarytoreversethe toolingifusingthelefthandedapplicationalong with thelocator.followthestepsbelow: 1. thelocatormustberemovedbeforereversingthe tooling. terminal figure 6 wire wire stop squeeze here squeeze here locator figure 7a top hooks top slots of handtool lower tabs make sure center of locator is in the down position figure 7b
handcrimptoolfor 1. 80mm(.071 ) pcboardcrimpterminal docno:ats638237100 releasedate:030111 uncontrolled copy page5of7 revision:a revisiondate:030111 match up marks front back figure 9 2. removethem3bhcswhichisholdingtheupper tooling. 3. fliptheuppertoolingtotheoppositesideandrep lace them3bhcs.makesurethesmallmarkingsonthe frontandbackofthehandtoolframematchupand areontheoutsideofthehandtoolframe.seefig ure 8and9. 4. dothesamethingwiththelowertoolingandtighte n them3screws.besurethesmallmarkingslineup. 5. reinstallthelocatorbyfollowingtheinstructions in thelocatorreplacementsection. maintenance itisrecommendedthateachoperatorofthetoolbe madeawareof,and responsiblefor,thefollowingmaintenancesteps: 1. removedust,moisture,andothercontaminantswith acleanbrush,orsoft, lintfreecloth. 2. donotuseanyabrasivematerialsthatcoulddamage thetool. 3. makecertainallpins;pivotpointsandbearingsur facesareprotectedwitha thincoatofhighqualitymachineoil.donotoil excessively.thetoolwas engineeredfordurabilitybutlikeanyotherequipm entitneedscleaningand lubricationforamaximumservicelifeoftroublef reecrimping.lightoil (suchas30weightautomotiveoil)usedattheoil points,every5,000 crimpsor3months,willsignificantlyenhancethe toollife. 4. wipeexcessoilfromhandtool,particularlyfromc rimpingarea.oiltransferredfromthecrimpingar eaonto certainterminationsmayaffecttheelectricalchar acteristicsofanapplication. 5. whentoolisnotinuse,keepthehandlesclosedto preventobjectsfrombecominglodgedinthecrimpi ngdies, andstorethetoolinaclean,dryarea. miscrimps or jams shouldthistooleverbecomestuckorjammedinap artiallyclosedposition, do not forcethehandlesopenorclosed. thetoolwillopeneasilyby pressingupontheratchetreleaseleverinthemov ablehandle.seefigure 11. how to adjust tool preload (see figure 12) thishandtoolisfactorypresetto2545lbs.prel oad.itmaybenecessary overthelifeofthetooltoadjusttoolhandlepre loadforce.listedbeloware thestepsrequiredtoadjustthecrimpingforceof thehandtooltoobtainpropercrimpconditions: 1. holdthehandtoolinthepalmofyourhandasshow ninfigure12.usingtheindexfingersqueezethe link towardsthetopofthehandtoolframe.thiswill releasethepreloadadjustmentwheel. lubrication points (both sides) light oil (every 3 months or 5,000 crimps) figure 10 ratchet release lever figure 11
handcrimptoolfor 1. 80mm(.071 ) pcboardcrimpterminal docno:ats638237100 releasedate:030111 uncontrolled copy page6of7 revision:a revisiondate:030111 figure 12 squeeze the link in the handle hold the hand tool in position setting wheel ratchet release lever 2. rotatethesettingwheelcounter clockwise(ccw)toincreasehandle force.thenumberswilldisplay higher.todecreasehandleforce rotatethesettingwheelclockwise (cw). 3. releasethelinktolockthesetting wheelinplace. 4. checkthecrimpspecificationsor conductapulltestaftertoolhandle preloadforceisadjusted. warranty thistoolisforelectricalterminalcrimping purposesonly.thistoolismadeofthe bestqualitymaterials.allvitalcomponentsarel onglifetested.alltoolsarewarrantedtobefre eofmanufacturing defectsforaperiodof30days.shouldsuchadef ectoccur,wewillrepairorexchangethetoolfree ofcharge. thisrepairorexchangewillnotbeapplicabletoa ltered,misused,ordamagedtools.thistoolisde signedfor handuseonly.anyclamping,fixturing,oruseof handleextensionsvoidsthiswarranty. caution :molexcrimpspecificationsarevalidonlywhenu sedwithmolexterminalsandtooling. cautions: 1. manuallypoweredhandtoolsareintendedforlowvo lumeorfieldrepair.thistoolis not intendedfor productionuse.repetitiveuseofthistoolshould beavoided. 2. insulatedrubberhandlesarenotprotectionagainst electricalshock. 3. weareyeprotectionatalltimes. 4. useonlythemolexterminalsspecifiedforcrimping withthistool. certification molexdoesnotcertifyorrecertifyhandtoolsbut rathersuppliesthefollowingguidelinesforcusto merstorecertify handtools. % thistoolisqualifiedtopullforceonly.seethe molexwebsiteforthequalitycrimphandbookfor more informationonpulltesting. % ifthetooldoesnotmeetminimumpullforcevalues ,handlepreloadshouldbeincreasedandthepullt est rerun,(seehowtoadjustpreload). % whenthehandtoolisnolongercapableofachievin gminimumpullforce,itshouldbetakenoutofser viceand replaced.
handcrimptoolfor 1. 80mm(.071 ) pcboardcrimpterminal docno:ats638237100 releasedate:030111 uncontrolled copy page7of7 revision:a revisiondate:030111 ratchet release lever 2 figure 13 1 3 parts list item number order number description quantity ref 638237100 handcrimptool figure13 1 638237175 locatorassembly 1 2 638100104 spring,return 1 3 638100105 spring,ratchet 1 http://www.molex.com
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