Hand Crimp Tool for 1CKT Led Conn Wire-to-Board Crimp Terminal
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63827-7600
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
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 RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1CKT Led Conn Wire-to-Board Crimp Terminal, 22-26 AWG.
Wire Size
Insulation Diameter (2)
Strip Length
Terminal
Terminal Order No.(1)
Series No.
AWG
mm²
mm
In.
mm
In.
505073
505073-0100 505073-1100 22-26 0.126-0.34
0.90-1.70
.035-.067
1.90-2.20 .075-.087
(1)
Customer to cut off terminal from reel: 0.1-1.0mm (.004-0.39”) maximum Cut-off Tab.
(2) See Conditions on page 2.
Note: Terminal will accommodate the UL1061 wires. For UL1007 wires, use Hand Crimp Tool No 63827-7500.
DEFINITION OF TERMS
BEND UP
STRIP LENGTH
BELL MOUTH
BRUSH
ROLLING
SEAM
BEND
DOWN
CUT-OFF
TAB
TWISTING
CONDUCTOR
CRIMP HEIGHT
WIRE
INSULATION CRIMP
SEE NOTE
▲
Doc No: ATS-638277600
Revision: A
Release Date: 03-10-15
Revision Date: 03-10-15
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool for 1CKT Led Conn Wire-to-Board Crimp Terminal
▲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).
PUNCH
OVERLAP FORM GEOMETRY
OVERLAP
INSULATIO
N
CRIMP
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No.
Wire Size
ANVIL
WIRE
Conductor Crimp
Insulation Crimp
Pull Force
Profile
Height
Width (Ref.) Height (Ref) Width (Ref) Minimum
AWG mm
2
mm
In.
mm
In.
mm
In. mm In.
N
Lb. 22 24 26
22
--- 0.78-0.83 0.31-0.33 1.27 0.05 1.95 .077 1.58 .062 39.2 8.81 X
505073
24
--- 0.70-0.75 0.27-0.29 1.27 0.05 1.92 .076 1.41 .056 29.4 6.61
X
26
--- 0.65-0.70 0.25-0.27 1.27 0.05 1.82 .072 1.40 .055 19.6 4.41
X
(2)
To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:
Profile 22 AWG: 1.22-1.27mm (.048-.050 inch)
Profile 24 AWG: 1.07-1.12mm (.042-.044 inch)
Profile 26 AWG: 0.97-1.03mm (.038-.041 inch)
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.
Note:
A crimp height chart is provided with this document
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.
HANDLE WILL
SPRING OPEN
LOCATOR
IN DOWN
POSTION
SQUEEZE
HANDLES
TOGETHER
Figure 1
Figure 2
PUSH ON THE
LOCATOR BUTTON
OPERATION
CAUTION:
Crimp only the Molex terminals listed in the scope for this tool. Do not crimp hardened objects as
damage can occur to the tool frame and/or crimp dies.
Doc No: ATS-638277600
Revision: A
Release Date: 03-10-15
Revision Date: 03-10-15
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool for 1CKT Led Conn Wire-to-Board Crimp Terminal
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.
LOCATOR
PUSHED THRU
TOOLING
LOCATOR
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
TERMINAL
Figure 3
TERMINAL
TOOLING
Crimping Terminals
PARTIALLY CLOSED
1. Select the desired terminal listed in the preceding charts.
PARTIALLY
2. Make sure the center of the locator is in the down position. With the
CLOSE HANDLE
locator attached, push the locator button on the back of the hand tool to
bring the locator forward through the tooling. See Figure 2.
OPEN
3. While holding the locator button in, load the terminal into the proper
POSITION
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.
FIRST
5. Close the tool handle until the first ratchet position engages. See
RATCHET
Figure 4.
POSITION
Figure 4
6. Insert the properly stripped wire above the terminal and against the wire
stop 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.
WIRE AGAINST THE
WIRE STOP IS PART
WIRE STOP
OF THE LOCATOR
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.
8. Remove the crimped terminal from the terminal locator by pulling on the wire.
9. Visually inspect the crimped terminal for proper crimp location.
Doc No: ATS-638277600
Revision: A
Release Date: 03-10-15
Revision Date: 03-10-15
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool for 1CKT Led Conn Wire-to-Board Crimp Terminal
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.
SQUEEZE
HERE
Figure 7A
LOCATOR
SQUEEZE
HERE
MAKE SURE
CENTER OF
LOCATOR
IS IN THE
DOWN POSITION
TOP SLOTS OF
HANDTOOL
TOP HOOKS
Figure 7B
LOWER TABS
JAWS OPEN
TOOLING
M3 BHCS
PULL OPEN
TOOLING
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
1. The locator must be removed before reversing the
HANDLE
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.
MATCH
UP MARKS
Figure 9
FRONT
BACK
Doc No: ATS-638277600
Revision: A
Release Date: 03-10-15
Revision Date: 03-10-15
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool for 1CKT Led Conn Wire-to-Board Crimp Terminal
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
Figure 10
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
RATCHET RELEASE
automotive oil) used at the oil points, every 5,000 crimps or 3 months, will
LEVER
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)
Miscrimps or Jams
Figure 11
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.
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
Figure 12
SETTING
WHEEL
Doc No: ATS-638277600
Revision: A
Release Date: 03-10-15
Revision Date: 03-10-15
UNCONTROLLED COPY
Page 5 of 7
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