0638271000 [MOLEX]
TOOL HAND CRIMPER 28-32AWG SIDE;
| 型号： | 0638271000 |
| 厂家： | 
Molex |
| 描述： | TOOL HAND CRIMPER 28-32AWG SIDE 连接器 连接器支架 |
| 文件： | 总7页 (文件大小：593K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Hand Crimp Tool for IllumiMate 1.25mm Wire-to-Board Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
TYPE 4D
Specification Sheet
Order No. 63827-1000
FEATURES
°
°
°
°
°
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision, user-friendly terminal locator holds terminals in the proper crimping position
Right and Left handed applications
Dies and Locator from this tool can be used in the Battery-Powered Tool Order No. 63816-0200 (110 V) or
63816-0250 (220 V) with the use of the 63816-0800 Crimp Head
Many different tool kits can be used with a single Battery-Powered Crimp Tool
This tool is IPC/WHMA A-620 Class 2 compliant
°
°
SCOPE
Products: IllumiMate 1.25mm Wire-to-Board Connector Crimp Terminals, 28-32 AWG.
Terminal Order No.
Wire Size
AWG
Insulation Diameter
mm In.
Strip Length
mm In.
Terminal Series No.
Loose Piece
Reel
104539-8102
104539
Not available
28-32
0.85 maximum .033 maximum 1.3-1.5 .051-.059
104539-8002
DEFINITION OF TERMS
BEND UP
TWISTING
STRIP LENGTH
BRUSH
BELL MOUTH
SEAM
ROLLING
BEND
DOWN
CUT-OFF
TAB
CONDUCTOR
CRIMP HEIGHT
INSULATION CRIMP
▲SEE NOTE
WIRE
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the scope.
Doc No: 638271000
Revision: C
Release Date: 01-03-14
Revision Date: 05-23-17
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool for IllumiMate 1.25mm Wire-to-Board Crimp Terminals
▲Insulation Crimp Note
Due to the terminal’s insulation grip design or
OVERLAP FORM GEOMETRY
PUNCH
insulation diameter range, this tool uses “overlap” form
geometry in the insulation punch. This produces an
overlap insulation crimp (A620-compliant). Although
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
CONDITIONS
After crimping, the conductor profiles should measure
the following:
WIRE
ANVIL
Conductor Crimp
Height (Ref.) Width (Ref.)
mm In. mm In.
Insulation Crimp
Height (Ref.) Width (Ref.)
mm In.
0.88-.094 .035-.037
Wire
Size
AWG
Pull Force
Minimum
Terminal
Series
No.
Profile
mm
In.
N
Lb. A B C
28 0.41-0.44 .016-.017
9.8 2.2
x
104539
30 0.38-0.42 .015-.016 0.70 .027
32 0.35-0.39 .014-.015
0.83-0.88 .033-.035 0.85
0.78-0.83 .031-.033
.035
5
3
1.1
0.7
x
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.
HANDLE WILL
SPRING OPEN
LOCATOR
IN DOWN
POSTION
Note:
A crimp height chart is provided with this document
as reference only. Because of 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.
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
OPERATION
Figure 1
CAUTION: Crimp only the Molex terminals
listed in the scope for this tool. Do not crimp hardened objects because damage can occur to the tool frame
or crimp dies.
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. See Figure 1.
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.
Doc No: 638271000
Revision: C
Release Date: 01-03-14
Revision Date: 05-23-17
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool for IllumiMate 1.25mm Wire-to-Board Crimp Terminals
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.
RELEASE
LOCATOR BUTTON
LOCATOR
PUSHED THROUGH
TOOLING
LOCATOR
BUTTON
PUSHED IN
TOOLING
PARTIALLY
CLOSED
LOCATOR
Figure 3
TERMINAL
PARTIALLY
TERMINAL
CLOSE HANDLE
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 locator.
See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism
cycle has been completed. Release the handles to open the jaws.
OPEN
POSITION
FIRST RATCHET
POSITION
LOCATOR
TERMINAL
Figure 4
PRE-STRIPPED
WIRE
WIRE AGAINST THE LOCATOR
LOCATOR
TERMINAL
Figure 5
MAKE SURE
CENTER OF
LOCATOR
IS IN THE
DOWN POSITION
Note: The tamper-proof ratchet action will not release
SQUEEZE
HERE
the tool until it has been fully closed.
8. Remove the crimped terminal from the terminal
locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper
crimp location.
SQUEEZE
HERE
Figure 6A
TOP SLOTS OF
HAND TOOL
Locator Replacement
TOP HOOKS
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:
Figure 6B
LOWER TABS
Doc No: 638271000
Revision: C
Release Date: 01-03-14
Revision Date: 05-23-17
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool for IllumiMate 1.25mm Wire-to-Board Crimp Terminals
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in Figure
6A 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 6A.
JAWS OPEN
PULL OPEN
TOOLING
M3 BHCS
TOOLING
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 6B.
Figure 7
6. Holding onto the lower part of the locator with
your thumb and index finger, insert the locator’s
top hooks (2) into the hand tool’s top slots.
7. Rotate the locator down, and press the lower tabs
PUSH ON
HANDLE
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.
MATCH
UP MARKS
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
Figure 8
if using the left handed application along with the locator.
Follow the steps below:
BACK
FRONT
1. The locator must be removed before reversing the
tooling.
2. Remove the M3 BHCS, which is holding the upper tooling.
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 tool frame. See
Figures 7 and 8.
4. Do the same thing with the lower tooling, and tighten the M3 screws.
Be sure the small markings line up.
5. Reinstall the locator by following the instructions in the locator
replacement section.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Maintenance
It is recommended that each operator of the tool be made aware of and
responsible for the following maintenance steps:
Figure 9
1. Remove dust, moisture and other contaminants with a clean brush or a
soft, lint-free cloth.
2. Do not use any abrasive materials that could damage the tool.
Doc No: 638271000
Revision: C
Release Date: 01-03-14
Revision Date: 05-23-17
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool for IllumiMate 1.25mm Wire-to-Board Crimp Terminals
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.
RATCHET RELEASE
LEVER
5. When the 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
pressing up on the ratchet release lever in the movable handle. See Figure
10.
Figure 10
How to Adjust Tool Preload (See
SQUEEZE
THE LINK IN
THE HANDLE
Figure 11)
HOLD THE HAND
TOOL IN POSITION
RATCHET
RELEASE LEVER
This hand tool is factory preset to 25-45
pounds 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 11. Using
your index finger, squeeze the link
Figure 11
toward the top of the hand tool frame.
This will release the preload
SETTING
WHEEL
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.
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, Molex 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.
Doc No: 638271000
Revision: C
Release Date: 01-03-14
Revision Date: 05-23-17
UNCONTROLLED COPY
Page 5 of 7
Hand Crimp Tool for IllumiMate 1.25mm Wire-to-Board Crimp Terminals
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 use 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 hand tools but rather supplies the following guidelines for customers to re-certify
hand tools:
% This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire that has been stripped 12.7mm
(.50”) long so that there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. See the Molex website 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
should be 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: 638271000
Revision: C
Release Date: 01-03-14
Revision Date: 05-23-17
UNCONTROLLED COPY
Page 6 of 7
Hand Crimp Tool for IllumiMate 1.25mm Wire-to-Board Crimp Terminals
PARTS LIST
Item Number Order Number
Description
Quantity
REF
63827-1000
63827-1075
63810-0104
63810-0105
Hand Crimp Tool Figure 12
1
2
3
Locator Assembly
Spring, Return
1
1
1
Spring, Ratchet
2
1
RATCHET
RELEASE LEVER
3
Figure 12
Application Tooling Support
Phone: (402) 458-TOOL (8665)
E-Mail: applicationtooling@molex.com
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other trademarks listed
herein belong to their respective owners.
Doc No: 638271000
Revision: C
Release Date: 01-03-14
Revision Date: 05-23-17
UNCONTROLLED COPY
Page 7 of 7
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