Molex 63823-7970 Manuel utilisateur

Hand Crimp Tool for 2.50mm Board-In Crimp Terminals

Doc No: ATS-63 2379HM Release Date: 09-02-10 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 10-14-10

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

COND.CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

Applicatio Tooli g

Specificatio Sheet

Modular Crimp Head

Order No. 63823-7970

Ha d Crimp Tool

Order No. 63823-7900

FEATURES

% A full cycle ratcheting hand tool ensures complete crimps

% Ergonomically designed soft handles

% Precisely designed crimping profiles with simple contact positioning

% Easy handling due to outstanding force ratio

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63 16-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63 16-0700).

% Can also be used in the Battery Powered Tool Order No.63 16-0200 (110 V) or 63 16-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63 16-0600).

SCOPE

Products: 2.50mm (.09 ") Board-In Crimp Terminal, 22-2 AWG, UL1007 and UL1569 wires.

Termi al

Series No.

Termi al Order No.





 Reel

Wire Size I sulatio Diameter

Strip Le gth

AWG

mm² mm I . mm I .

35047 35047-9 00

35047-9 02

22-2

0.33-0.0

1.15-1.90 .045-.075 2.40-2.90

.094-.114

35047-9 10

 Insulation crimp to meet IPC/WHMA-A-620 Class 2 compliance.

Note: Terminal will accommodate the UL1007 and UL1569 wires.

 Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.

DEFINITION OF TERMS

The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the

scope.

TYPE 4A

Hand Crimp Tool for 2.50mm Board-In Crimp Terminals

Doc No: ATS-63 2379HM Release Date: 09-02-10 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 10-14-10

▲I sulatio 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).

CRIMP SPECIFICATIONS:

Termi al Series No. Bell mouth Co ductor Brush Max.

mm I . mm I .

35047 0.20-0.50 .00 -.020 1.40 .055

Termi al Series No. Be d up Be d dow Twist Roll Seam

Seam shall not be open

and no wire allowed out

of the crimping area

Degree Degree

35047 3 3 3 3

After crimping, the conductor profile should measure the following.

Termi al

Series No.

Wire Size

Co ductor Crimp I sulatio Crimp Pull Force

Mi imum Profile AWG

Height Width Height (Ref) Width

Maximum

AWG

mm2

mm I . mm I . mm I . mm

I . N Lb.

35047

22 0.33

0. 2-0. 7

.032-.034

1.30-1.50

.051-.059

1.70 Max

.067 Max

1.90

.075

39.1

. 0

24 0.20

0.75-0. 0

.029-.031

1.30-1.50

.051-.059

1.60 Max

.063 Max

1.90

.075

29.3

6.60

26 0.13

0.70-0.75

.027-.029

1.30-1.50

.051-.059

1.55 Max

.061 Max

1.90

.075

19.6

4.40

2 0.0

0.66-0.71

.026-.02

1.30-1.50

.051-.059

1.50 Max

.059 Max

1.90

.075

9. 2.20

• 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.

OPERATION

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.

1. With the hand tool in the open position, pivot

the terminal locator open by pulling up on the

locator knob and lift the wire stop blade up.

See Figure 1.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP BLADE

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for 2.50mm Board-In Crimp Terminals

Doc No: ATS-63 2379HM Release Date: 09-02-10 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 10-14-10

INCORRECT

Figure 5

CORRECT INCORRECT

PIVOT

LOCATOR

Figure 4

REMOVE

CRIMPED

WIRE

Figure 3

WIRE

TERMINAL

LOCATOR INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR

ANVIL

CONDUCTOR PUNCH

WIRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Figure 2

2. Insert the terminal into the correct profile until the terminal is fully seated and stops. Make sure the wire

stop blade is fully in up position.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade. Make sure the wire stop blade is fully seated on the terminal behind the

conductor grip section.

5. Slide the pre-stripped wire into the terminal; make sure to aim the wire brush towards the tip point on the

wire stop blade. See Figure 2. Align the wire so that it is parallel and sitting into the terminal. Maintain a

light and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the

wire.) Be sure to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases, the tool handles will then spring open.

7. Lift the wire stop blade up.

. Carefully remove the crimped terminal. Pivot the terminal locator slightly out if necessary. See Figure 4.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.

Hand Crimp Tool for 2.50mm Board-In Crimp Terminals

Doc No: ATS-63 2379HM Release Date: 09-02-10 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 10-14-10

Termi al Locator Replaceme t

This section describes the procedure for changing locators.

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 6.

I stallatio

1. Place the replacement locator on the hand tool. Install the M4

BHCS. See Figure 6.

2. Tighten the screw enough to hold the locator. Make sure the

locator can still float freely with hand pressure.

3. Insert the proper terminal fully into the correct profile slot until the

terminal is fully seated and stops. Then gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place and slowly tighten the M4 BHCS.

Mai te a ce

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 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.

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.

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 lifting the ratchet release lever. See Figure 10.

Warra ty

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.

M4 BHCS

PIVOT LOCATOR

Figure 6

Hand Crimp Tool for 2.50mm Board-In Crimp Terminals

Doc No: ATS-63 2379HM Release Date: 09-02-10 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 10-14-10

CAUTION: Repetitive use of this tool should be avoided.

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.

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding, and insulation types may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty above). The replacement parts listed are the only parts

available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 63 00-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

Applicatio s for the Modular Crimp Head

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.

CAUTION: Wear safety glasses when operating or serving this tool.

Hand Crimp Tool for 2.50mm Board-In Crimp Terminals

Doc No: ATS-63 2379HM Release Date: 09-02-10 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 10-14-10

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR

POWER

CRIMP

ADAPTER

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order o.

Tool

Descriptio

Adapter

Order No.

Adapter

Descriptio

Figure

No.

63 23-7970

63 16-0000

Hand Crimp Frame (Short) N/A N/A 7

63 16-0050

Hand Crimp Frame (Long) N/A N/A 7

63 16-0200

Battery Power Tool (110 V)

63 16-0600

Battery Power Crimp Adapter

63 16-0250

Battery Power Tool (220 V)

63 16-0600

Battery Power Crimp Adapter

63 16-0100

Air Power Tool 63 16-0700

Air Power Crimp Adapter 9

Applicatio s for the Modular Crimp Head

Ha d Crimp Tool Battery Powered Tool Air Powered Tool

Figure 7 Figure 8 Figure 9

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for 2.50mm Board-In Crimp Terminals

Doc No: ATS-63 2379HM Release Date: 09-02-10 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 10-14-10

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

1 4

Figure 10

M4 X 8mm

LONG BHCS

PARTS LIST

Ha d Crimp Tool 63823-7900

Item

Order Number

Descriptio Qua tity

1 63 23-7970 Modular Crimp Head 1

2 63 16-0000 Hand Crimp Frame (Short)

3 63 23-7975 Locator 1

4 63 16-0001 Locking Pin 2

5 63600-0525 Handle Spring 1

6 63600-0520 Crimping Spring 2

http://www.molex.com

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