Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
Order No. 63827-7700
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 RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal, 26-30 AWG.
Terminal Series No.
Wire Size
Terminal Order No.
Reel Form Only (1) AWG
mm²
Insulation Diameter (2)
mm
In.
Strip Length
mm
In.
1.40-1.60 .055-.062
505263
505263-1000
26-30 0.079-0.136 0.78-1.02 .031-0.40
(1)
Customer to cut off terminal from reel: 0.10mm (.004”) maximum Cut-Off Tab.
(2)
See Conditions on page 2.
DEFINITION OF TERMS
BEND UP
STRIP LENGTH
BRUSH
BELL MOUTH
TWISTING
ROLLING
SEAM
CUT-OFF
TAB
CONDUCTOR
CRIMP HEIGHT
BEND
DOWN
INSULATION CRIMP
WIRE
Doc No: 638277700
Revision: B
Release Date: 02-20-15
Revision Date: 05-24-17
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal
CONDITIONS
After crimping, the conductor profiles should measure the following:
Conductor Crimp
Insulation Crimp
Pull Force
Terminal
Wire Size
Profile
Series
Height
Width (Ref.)
Height
Width (Ref.) Minimum
No.
AWG mm
2
mm
In.
mm In.
mm
In.
mm In.
N
Lb. 26 28 30
26
— 0.54-0.59 .021-.023 0.85 .033 1.19-1.28 .047-.050 0.95 .037 9.8 2.20 X
505263
28
— 0.49-0.54 .019-.021 0.85 .033 1.18-1.28 .046-.050 0.95 .037 9.8 2.20
X
30
— 0.46-0.51 .018-.020 0.85 .033 1.08-1.18 .043-.046 0.95 .037 4.9 1.10
X
To achieve IPC-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:
•
Profile 26 AWG:
0.95-1.02mm (.037-.040 inch)
•
Profile 28 AWG:
0.80-0.95mm (.031-.037 inch)
•
Profile 30 AWG:
0.75-0.95mm (.029-.037 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. 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.
HANDLE WILL
SPRING OPEN
LOCATOR
IN DOWN
POSTION
OPERATION
CAUTION:
Crimp only the Molex terminals
Figure 1
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.
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
Figure 2
PUSH ON THE
LOCATOR BUTTON
Doc No: 638277700
Revision: B
Release Date: 02-20-15
Revision Date: 05-24-17
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal
LOCATOR
PUSHED THROUGH
TOOLING
LOCATOR
BUTTON
PUSHED IN
RELEASE
LOCATOR
BUTTON
LOCATOR
TERMINAL
Figure 3
TERMINAL
TOOLING
PARTIALLY CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
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 above 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.
LOCATOR
TERMINAL
PRE-STRIPPED
WIRE
FIRST
RATCHET
POSITION
Figure 4
TERMINAL
Figure 5
WIRE AGAINST THE LOCATOR
Note:
The tamper-proof ratchet action will not release the tool until it has been fully closed.
LOCATOR
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
SQUEEZE
HERE
Figure 7A
TOP SLOTS OF
HANDTOOL
TOP HOOKS
MAKE SURE
CENTER OF
LOCATOR
IS IN THE
DOWN POSITION
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.
Figure 7B
LOWER TABS
Doc No: 638277700
Revision: B
Release Date: 02-20-15
Revision Date: 05-24-17
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal
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 locator’s top
hooks (2) into the hand tool’s 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
M3 BHCS
TOOLING
Figure 8
PUSH ON
HANDLE
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 Figures 8
and 9.
MATCH
UP MARKS
Figure 9
FRONT
BACK
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.
Doc No: 638277700
Revision: B
Release Date: 02-20-15
Revision Date: 05-24-17
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to-Board Crimp Terminal
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 a soft,
lint-free cloth.
2. Do not use any abrasive materials that could damage the tool.
LUBRICATION POINTS
3. Make certain all pins, pivot points and bearing surfaces are protected with a
(BOTH SIDES) LIGHT OIL
thin coat of high-quality machine oil. Do not oil excessively. The tool was
(EVERY 3 MONTHS OR
5,000 CRIMPS)
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
Figure 10
or 3 months will significantly enhance the tool life.
4. Wipe excess oil from hand tool, particularly from the crimping area. Oil transferred from the crimping area onto
certain terminations may affect the electrical characteristics of an application.
5. When the tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping
RATCHET RELEASE
dies, and store the tool in a clean, dry area.
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)
Figure 11
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
RATCHET
hand as shown in Figure 10. Using
RELEASE LEVER
your index finger, squeeze the link
toward 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
SETTING
wheel in place.
WHEEL
4. Check the crimp specifications or
conduct a pull test after tool handle preload force is adjusted.
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
Figure 12
Doc No: 638277700
Revision: B
Release Date: 02-20-15
Revision Date: 05-24-17
UNCONTROLLED COPY
Page 5 of 7
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