63825-1200 Appl Tooling Spec Datasheet

molex ' D 0 A io in S a e e 25 R A c in e p gono ip c A on ie inal e 5 er he p a hand ion 0 H Cla plia e o 0 how 0 no Products: 1 059 K e i inal, G Terminal Terminal Order No. Wire Size #lnsulation Diameter Strip Length Series No. Loose *Reel AWG mm2 mm In. mm In. 50 0000 0. 02 .059 9% Customer to cut offlerminal from reei 0. mm (.0 ") maximum Cut offTab OSee Conditions on page 2. | ER BEND UP CONDUCTOR ROLLING BELL MOUTH CRIMP , \ l :77 msuumou ‘0 CRIMP \ x’ 1 , ‘\ *i K, .1 “J D N CRIMP HEIGHT e aw gene r ion an 9 ed
Hand Crimp Tool for
Doc No
Revision:
Hand Crimp Tool for
Doc No
: ATS-
638
Revision:
A
HAND CRIMP
TOOL
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user
Right and Left handed applications
This tool is IPC/WHMA A
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products:
1.50
Terminal
Series No.
50
scope.
Hand Crimp Tool for
1.50
mm (.0
638
251200
BRUSH
STRIP
LENGTH
HAND CRIMP
TOOL
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user
-
friendly
Right and Left handed applications
This tool is IPC/WHMA A
This tool is RoHS compliant, however RoHS compliant is not required
1.50
mm
(.059
Terminal
Series No.
50
3429
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
mm (.0
59
") Pitch
Release Date:
Revision Date:
BELL MOUTH
Application Tooling
Specification S
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
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 as indicated
This tool is RoHS compliant, however RoHS compliant is not required
(.059
") Pitch
CLIK
Terminal Order No.
Loose
-
Customer to cut off terminal from reel: 0.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
") Pitch
CLIK-Mate
Release Date:
02-14-13
Revision Date:
02-14-13
INSULATION
CRIMP
BELL MOUTH
Application Tooling
Specification S
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
terminal locator wire stop holds terminals in the proper crimping position
Right and Left handed applications
620 Class 2 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
CLIK
-Mate
™ Wire
Terminal Order No.
Reel
503429-0000
Customer to cut off terminal from reel: 0.
See Conditions on page 2.
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
Wire-to-
Board Crimp Terminal
UNCONTROLLED COPY
INSULATION
CRIMP
CONDUCTOR
CRIMP
Application Tooling
Specification S
heet
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
terminal locator wire stop holds terminals in the proper crimping position
620 Class 2 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
Wire
-to-
Board Crimp Terminal
Wire Size
AWG
mm²
26-30
0.12-
0.
Customer to cut off terminal from reel: 0.
10
mm (.0
See Conditions on page 2.
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
Board Crimp Terminal
UNCONTROLLED COPY
CRIMP HEIGHT
CONDUCTOR
CRIMP
Application Tooling
heet
terminal locator wire stop holds terminals in the proper crimping position
620 Class 2 compliant as indicated
This tool is RoHS compliant, however RoHS compliant is not required
Board Crimp Terminal
,
Wire Size
Insulation Diameter
mm²
mm
0.
05
0.70-1.
02
mm (.0
04
) maximum Cut
See Conditions on page 2.
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
Board Crimp Terminal
UNCONTROLLED COPY
CRIMP HEIGHT
BEND
DOWN
BEND UP
Order No.
terminal locator wire stop holds terminals in the proper crimping position
,
26 - 30 A
WG
Insulation Diameter
In.
02
.028-.040
) maximum Cut
-
off Tab.
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
BEND UP
ROLLING
TWISTING
Order No.
6382
5
terminal locator wire stop holds terminals in the proper crimping position
WG
Strip Length
mm
1.50-1.90
.0
59
off Tab.
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
TYPE 4D
Page 1 of
8
ROLLING
5
-1200
Strip Length
In.
59
-.075
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
TYPE 4D
8
Conductor Crimp Insulation Crimp Height (Rat) Width (Rafi) Height (Rafi) Width (Rafi) mm In. mm In. mm In. mm In. 0 54-059 .021- 023 0 89 .035 1.25 .049 1 15 .045 0 50-055 .020- 022 0 89 .035 1.17 .046 1 14 .045 0.52 020 ‘ , _ POSTION SPRING OPEN . \
Hand Crimp Tool for 1.50mm (.059") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal
Doc No: ATS-638251200 Release Date: 02-14-13 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 02-14-13
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No.
Wire Size Conductor Crimp Insulation Crimp Pull Force
Minimum Profile
Height (Ref.) Width (Ref.)
Height (Ref.)
Width (Ref.)
AWG
mm2
mm In. mm In. mm In. mm In. N Lb. 26
28
30
503429
26 0.54-0.59
.021-.023
0.89 .035 1.25 .049 1.15 .045 19.6
4.40
X
28 0.50-0.55
.020-.022
0.89 .035 1.17 .046 1.14 .045 9.8 2.20
X
30 0.47-0.52
.018-.020
0.88 .035 1.13 .044 1.12 .044 4.9 1.10
X
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile 26: 0.75 - 1.02mm (.037-.043 inch)
Profile 28: 0.70 – 0.90mm (.045-.051 inch)
Profile 30: 0.70 – 0.85mm (.045-.051 inch)
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
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 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.
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.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
SE BUTTON
Hand Crimp Tool for 1.50mm (.059") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal
Doc No: ATS-638251200 Release Date: 02-14-13 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 02-14-13
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
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.
7. Crimp the terminal by squeezing the tool handles until the ratchet
mechanism cycle has been completed. Release the handles to open
the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
Reference On‘y. t/‘TOOLING Figure 8 N HANDI F
Hand Crimp Tool for 1.50mm (.059") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal
Doc No: ATS-638251200 Release Date: 02-14-13 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 02-14-13
Figure
8
PUSH ON
HANDLE
JAWS OPEN
PULL
TOOLING
TOOLING
M3 BHCS
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.
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 Replacement
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.
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.
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
Hand Crimp Tool for 1.50mm (.059") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal
Doc No: ATS-638251200 Release Date: 02-14-13 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 02-14-13
MATCH
UP MARKS
FRONT BACK
Figure 9
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:
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 Figure 8
and 9.
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.
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.
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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
Hand Crimp Tool for 1.50mm (.059") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal
Doc No: ATS-638251200 Release Date: 02-14-13 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 02-14-13
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
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 counter-
clockwise (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
Figure 11
CAUTIONS:
Hand Crimp Tool for 1.50mm (.059") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal
Doc No: ATS-638251200 Release Date: 02-14-13 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 02-14-13
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.
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, 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 no faster than
25mm (1.00”) per minute. 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.
63810-0105 5 rin ,Ratchel O
Hand Crimp Tool for 1.50mm (.059") Pitch CLIK-Mate™ Wire-to-Board Crimp Terminal
Doc No: ATS-638251200 Release Date: 02-14-13 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 02-14-13
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 63825-1200 Hand Crimp Tool Figure 13
1 63825-1275 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
http://www.molex.com