Application Tooling Specification Sheet HAND CRIMP

Application Tooling Specification Sheet  HAND CRIMP
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63819-0000
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
Right and Left handed applications
This tool is IPC/WHMA A-620 Class 2 compliant
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: Micro-Fit 3.0™ Crimp Terminals, 20-30 AWG.
Terminal
Series No.
43030
43031
44372
45773
Terminal Order No.
Wire Size
Insulation Diameter
Reel
Loose Piece
AWG
mm²
mm
In.
43030-0007
43030-0001
43030-0009
43030-0003 20-24 0.50-0.20 1.42-1.85 .056-.073
43030-0008
43030-0002
43030-0010
43030-0004
43030-0012
43030-0006 26-30 0.12-0.05 1.09-1.27 .043-.050
43030-0011
43030-0005
43031-0007
43031-0001
43031-0009
43031-0003 20-24 0.50-0.20 1.42-1.85 .056-.073
43031-0008
43031-0002
43031-0010
43031-0004
43031-0012
43031-0006 26-30 0.12-0.05 1.09-1.27 043-.050
43031-0011
43031-0005
44372-0002
20-24 0.50-0.20 1.30-1.85 .051-.073
45773-0001 45773-0003
20-24 0.50-0.20 1.42-1.85 .056-.073
45773-0002 45773-0053
45773-0004
45773-0006 26-30 0.12-0.05 1.09-1.27 043-.050
45773-0005
Customer to cut off terminal from reel: 0.18mm (.007”) maximum Cut-off Tab.
2.54-2.92 .100-.115
2.54-2.92 .100-.115
2.54-2.92 .100-.115
2.54-2.92 .100-.115
BEND UP
DEFINITION OF TERMS
BRUSH
Strip Length
mm
In.
BELL MOUTH
CONDUCTOR
CRIMP
INSULATION
CRIMP
▲SEE NOTE
ROLLING
TWISTING
STRIP
LENGTH
BEND
DOWN
CRIMP HEIGHT
Doc No: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 1 of 8
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
OVERLAP FORM GEOMETRY
PUNCH
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 – compliant). While
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
WIRE
ANVIL
CONDITIONS:
After crimping, the conductor profiles should measure the following. See Notes below.
Terminal
Series No
43030
43031
44372
45773
Wire Size
AWG
20
22
24
26
28
30
20
22
24
26
28
30
20
22
24
20
22
24
26
28
30
mm2
0.50
0.35
0.20
0.12
0.08
0.05
0.50
0.35
0.20
0.12
0.08
0.05
0.50
0.35
0.20
0.50
0.35
0.20
0.12
0.08
0.05
Conductor Crimp
Insulation Crimp
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.)
mm
In.
mm
In.
mm
In.
mm
In.
0.89-0.99 .035-.040 1.40 .055 1.70 .067 1.83 .072
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.41 .056
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.40 .055
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.40 .055
0.89-0.99 .035-.040 1.40 .055 1.70 .067 1.83 .072
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.41 .056
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.40 .055
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.40 .055
0.89-0.99 .035-.040 1.40 .055 1.70 .067 1.83 .072
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.89-0.99 .035-.040 1.40 .055 1.70 .067 1.83 .072
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.83-0.93 .033-.037 1.40 .055 1.58 .062 1.72 .068
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.41 .056
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.40 .055
0.70-0.80 .028-.031 1.10 .043 1.38 .054 1.40 .055
Pull Force
Profile
Minimum
N
Lb. 20 22-24 26-30
57.8 13.00 X
35.6 8.00
X
22.2 5.00
X
13.3 3.00
X
8.9 2.00
X
6.7 1.50
X
57.8 13.00 X
35.6 8.00
X
22.2 5.00
X
13.3 3.00
X
8.9 2.00
X
6.7 1.50
X
57.8 13.00 X
35.6 8.00
X
22.2 5.00
X
57.8 13.00 X
35.6 8.00
X
22.2 5.00
X
13.3 3.00
X
8.9 2.00
X
6.7 1.50
X
• Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Doc No: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 2 of 8
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
Note:
A crimp height chart is provided with this manual
as Reference Only. Due to the wide range of
wires, strands, insulation diameters, and
durometers available, actual crimp height
measurements may very slightly. An
occasional, destructive, pull force test should be
performed to check hand tool crimp. Pull Force
value Must exceed the Minimum pull force
specifications listed.
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
SQUEEZE
HANDLES
TOGETHER
OPERATION
Figure 2
PUSH ON THE
LOCATOR BUTTON
Open the tool by squeezing the handles
Figure 1
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
PUSHED THRU
TOOLING
RELEASE
LOCATOR
BUTTON
LOCATOR
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Figure 3
TERMINAL
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 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 tooling. See Figure 3.
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.
Doc No: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
Figure 4
UNCONTROLLED COPY
Page 3 of 8
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws.
WIRE STOP IS PART
OF THE LOCATOR
WIRE AGAINST THE
WIRE STOP
TERMINAL
PRE-STRIPPED
WIRE
Figure 5
WIRE
TERMINAL
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
then close the tool. See Figure 6.
WIRE STOP
Figure 6
TERMINAL
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 crimp hand 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 red insert down as far as it will go as
shown in Figure 7B.
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
TOP HOOKS
Figure 7B
LOWER TABS
Doc No: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 4 of 8
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
6. Holding onto the lower part of the locator with your
thumb and index finger, insert the locators top
hooks (2) into the hand tool 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.
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
Right or Left Hand 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:
Figure 8
PUSH ON
HANDLE
1. The locator must be removed before reversing the tooling.
2. Remove the M3 BHCS which is holding the upper
MATCH
tooling.
UP MARKS
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
Figure 9
tool frame. See Figure 8 and 9.
4. Do the same thing with the lower tooling and
tighten the M3 screws. Be sure the small markings
FRONT
line up.
5. Reinstall the locator by following the Instructions in the locator replacement section.
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
soft, lint free cloth.
2. Do not use any abrasive materials that could damage the tool.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
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
Figure 10
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.
4. Wipe excess oil from 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 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.
Doc No: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 5 of 8
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
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.
How to Adjust Tool Preload (See Figure 12)
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. Hold the hand tool in the palm of your
hand as shown in Figure 10. Using
the index finger squeeze the link
towards 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
Figure 11
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, we 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 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: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 6 of 8
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
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 web site 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: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 7 of 8
Hand Crimp Tool For Micro-Fit 3.0™ Crimp Terminals
PARTS LIST
Item Number
REF
1
2
3
Order Number
63819-0000
63819-0075
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
RATCHET
RELEASE LEVER
Figure 13
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638190000
Revision: D
Release Date: 10-11-07
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 8 of 8
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