Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4E
Order No. 63827-1200
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
This tool is IPC/WHMA A-620 Class 2 compliant
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products, Quick Disconnect, Female Crimp Terminal for 1.00-2.50mm²
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter Max.(2)
Strip Length
Reel Form only (1)
mm
2
AWG
mm
In.
mm
In.
94030-3910 94030-3911
94030
1.00-2.50
-
3.70
.146
5.30-6.30 .209-.248
94030-3912 94030-3913
(1) Customer to cut off terminal from reel: 0.30mm (.012”) maximum cut-off tab (both ends)
(2) To achieve optimum IPC-A620 insulation crimps, use insulation OD range: 2.40-3.70mm (.095”-.146”)
DEFINITION OF TERMS
WIRE
STRIP LENGTH
BRUSH
BELLMOUTH
SEAM
BEND
UP
CUT-OFF
TAB
TWISTING
ROLLING
BEND
DOWN
INSULATION CRIMP
▲SEE
NOTE
CONDUCTOR
CRIMP HEIGHT
Doc No: ATS-638271200
Revision: A
Release Date: 12-04-13
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
CONDITIONS:
Terminal Series No.
94030
Bell mouth
mm
In.
0.30-0.60 .012-.024
Conductor Brush
mm
In.
0.30-1.00 .012-.039
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
Terminal Series No.
94030
Bend up Bend down
Degree Max.
3
3
Twist Roll
Degree Max.
4
8
After crimping, the conductor profiles should measure the following.
Terminal
Series No.
94030
Conductor Crimp
Height
Width Max.
mm
2
AWG
mm
In.
mm In.
1.00
-
1.50-1.60 .059-.063 2.95 .116
1.50
-
1.65-1.75 .065-.069 2.95 .116
2.50
-
1.77-1.87 .070-.074 2.95 .116
Wire Size
Insulation Crimp
Height (Ref.) Width (Ref.)
mm
In.
mm In.
3.15 .124 3.50 .138
3.45 .136 3.75 .148
3.60 .142 4.10 .161
Pull Force
Profile
Minimum
N
Lb. 1.5mm2 2.5mm2 1.0mm2
156.8 35.3
X
196.0 44.1
X
245.0 55.1
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.
OVERLAP FORM GEOMETRY
PUNCH
▲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
ANVIL
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
WIRE
CAUTION:
Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.
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.
Doc No: ATS-638271200
Revision: A
Release Date: 12-04-13
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
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. See Figure 1.
PUSH
LEVER TO
RAISE WIRE
STOP
INSERT
TEMINAL
Crimping Terminals
1. Select the desired terminal listed in the
preceding charts.
HANDLES
Figure 2
2. Push the wire stop lever on the side of the hand
OPEN
tool to raise the wire stop up before inserting the
Figure 1
terminal in the hand tool. See Figure 2.
3. With the wire stop lever pushed in, load the
terminal into the proper nest opening marked
with the wire gauge on the hand tool. See Figure 2.
4. Next release the wire stop lever, allowing the wire stop to return to the crimping position.
5. Insert the properly stripped wire through the terminal and against the wire stop. See Figure 3.
LOCATOR
TERMINAL
PRE-STRIPPED
WIRE
WIRE AGAINST
THE WIRE STOP
WIRE
RELEASE
THE
LEVER
TERMINAL
Figure 3
6. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release the handles to open the jaws. See Figure 4.
Note:
The tamper proof ratchet action will not release the tool until it has been
fully closed.
7. Push the wire stop lever in to raise the wire stop up and remove the crimped
terminal from the locator by lifting up and then pulling the wire out.
8. Visually inspect the crimped terminal for proper crimp location.
LEVER
UP
SQUEEZE
HANDLES
TOGETHER
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 and turn the tool upside down on the back side.
2. Remove the tightening lock nut.
Figure 4
Doc No: ATS-638271200
Revision: A
Release Date: 12-04-13
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
3. Remove the locator assembly from the frame head.
4. To reinstall the new locator, make sure the hand tool is in the open
position.
5. Replace the locator assembly into the frame head.
6. Reinstall the tightening lock nut.
MATCH
UP MARKS
MATCH
UP MARKS
Remove and Install Tooling
1.
2.
3.
4.
5.
6.
Make sure the tool is in open position before remove or install tooling.
The locator must be removed before remove or install tooling.
Remove the M3 screw which is holding the upper tooling.
Remove or install upper tooling through the back side of the tool
frame.
Install the M3 screw. Make sure the small markings on the front of the
hand tool frame match up. See Figure 5.
Follow step 3 to 5 for the lower tooling except through the front side of
the tool frame and install the M3 screw. Be sure the small markings
on the lower tooling line up with upper tooling.
Slowly close the tool handles to align upper and lower tooling
together. Tighten the M3 screws and continue squeezing the tool
handles until the hand tool swings open.
Reinstall the locator by following the Instructions in the locator
replacement section.
Figure 5
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY 3 MONTHS
OR 1,000 CRIMPS)
Figure 6
7.
8.
Maintenance
It is recommended that each operator of the tool be made
aware of, and responsible for, the following maintenance steps:
See Figure 6.
RATCHET
RELEASE LEVER
1. Un-snap the 2 Snap-On plastic covers front and back.
SMALL
2. Remove dust, moisture, and other contaminants with a
FLAT HEAD
clean brush, or soft, lint free cloth.
SCREWDRIVER
3. Do not use any abrasive materials that could damage the
tool.
4. 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
HANDLES SHOULD BE
PARTIALLY CLOSED
but like any other equipment it needs cleaning and
lubrication for a maximum service life of trouble free
Figure 7
crimping. Light oil (such as 30 weight automotive oil) used
at the oil points, every 1,000 crimps or 3 months, will significantly enhance the tool life.
5. 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.
6. 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.
Doc No: ATS-638271200
Revision: A
Release Date: 12-04-13
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
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 using a small flat screwdriver pressing up on the ratchet release lever in the
movable handle. The handle should be partially closed.
See Figure 7.
How to Adjust Tool Preload
See Figure 8
This hand tool is factory preset to 210 N (47 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:
RATCHET
RELEASE LEVER
RATCHET
RELEASE
LEVER
FLAT HEAD
SCREWDRIVER
1. Open the tool by squeezing the handles together
ECCENTRIC AXLE
until the ratchet mechanism release, the hand tool
handles will spring open.
Figure 8
2. Remove the M3 screw and the M3 washer.
3. Lift the setting wheel off the axle. Use a small flat
SETTING
head screwdriver to turn the eccentric axle counter-
WHEEL
M3 x 6 LONG
clockwise (CCW) to increase handle force.
SCREW
WASHER
4. To decrease handle force, turn the eccentric axle
clockwise (CW).
5. Line up the setting wheel matching the flat side with
the flat edge of the axle so the wheel notch will drop onto the roll pin. The numbers will display higher.
6. Re-install the M3 washer and M3 screw.
7. Re-crimp a new sample and 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, 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.
Doc No: ATS-638271200
Revision: A
Release Date: 12-04-13
Revision Date: 12-04-13
UNCONTROLLED COPY
Page 5 of 7
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