Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
Tool Kit
Order No. 63819-3270
FEATURES
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Application Tooling
Specification Sheet
TYPE 2C
Hand Crimp Tool
Order No. 63819-3200
A full cycle ratcheting hand tool ensures complete crimps
Ergonomically designed soft handles
Precisely designed crimping profiles with simple contact positioning
Easy handling due to outstanding force ratio
Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
Many different Tool kits can be used with a single Battery Powered Tool.
This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
SCOPE
Products: Quick Disconnect, Female, Flag, for 0.50 and 0.80mm² (20 and 18 AWG) wires.
Terminal Terminal Order No.
Series No.
Reel
94030
Wire Size
Insulation Diameter
Strip Length
AWG
mm²
mm
In.
mm
In.
0.50
94030-5000
20
(0.52)
2.10-2.60 .083-.102 6.0-7.0 .236-.276
94030-5001
0.80
18
(0.82)
Customer to cut off terminal from reel. Cut tab flush with terminal on both ends.
STRIP
LENGTH
DEFINITION OF TERMS
SEAM
CONDUCTOR
CRIMP
WIRE
INSULATION
CRIMP
Doc No: ATS-6381932HM Release Date: 03-23-09
Revision: B
Revision Date: 10-04-10
UNCONTROLLED COPY
Page 1 of 8
Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes below).
Terminal
Series No.
Wire Size
AWG mm
2
0.50
20 (0.52)
0.80
18 (0.82)
Conductor Crimp
Profile
Height (Ref.)
Width (Ref.)
mm
In.
mm
In. A B
1.40 - 1.50 .055 - .059 2.35 .093
X
1.40 - 1.50 .055 - .059 2.35 .093
X
1.50 – 1.60 .059 - .063 2.35 .093
X
1.50 – 1.60 .059 - .063 2.35 .093
X
Pull Force
Minimum
N
Lb.
78.45 17.6
78.45 17.6
117.68 26.4
117.68 26.4
94030
Terminal
Series No.
Wire Size
AWG mm
2
0.50
20 (0.52)
0.80
18 (0.82)
94030
Insulation Crimp
Height (Ref.)
Width (Ref.)
mm
In.
mm
In.
2.80 – 2.90 .110 - .114 3.45 max .136 max
2.80 – 2.90 .110 - .114 3.45 max .136 max
2.90 – 3.00 .114 - .118 3.45 max .136 max
2.90 – 3.00 .114 - .118 3.45 max .136 max
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 manual as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the
minimum pull force specifications listed.
CAUTION:
Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head
follow the steps below:
PUNCHES
POWER
CRIMP
HEAD
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the
nest. Install the M4 x 10 long BHCS and tighten
in place.
2. Insert the Punches into the top slots of the nest.
Install the M4 x 18 long BHCS and tighten in
place. See Figure 1.
ANVILS
M4 X 18 LONG
BHCS
M4 X 10 LONG
BHCS
Figure 1
Doc No: ATS-6381932HM Release Date: 03-23-09
Revision: B
Revision Date: 10-04-10
UNCONTROLLED COPY
Page 2 of 8
Tool Kit for Quick Disconnect, Female, Flag 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.
KNURLED FASTENER
JAWS
OPEN
UPPER
TOOLING
Crimping Terminals
TERMINAL
1. Select the desired terminal listed in the preceding charts.
2. Before attempting to crimp any terminals, make sure all the upper
tooling is correctly placed into the upper jaw. The desired nest
being used for the proper wire size should be in the forward
position, (The marking on the upper tooling “A” for 0.8mm
²
or “B”
Figure 2
for 0.5mm²). This is done by removing the knurled fastener that
holds the upper tooling in place and then rotating it 180° to the correct position. Then, re-installing the
fastener. See Figure 2.
3. Place the terminal into the nest profile, centered on the nest as shown, with the outer edges of the crimp grips
flush with each side of the crimp die and the opening in the terminal centered below the forward leg of the right
punch. See Figure 3.
4. Partially close the tool until the terminal is held in place and re-position the terminal as necessary.
5. From the
left side of the tool,
insert the pre-stripped wire into the terminal until the conductor is centered, front
to rear, in the crimp grips. See Figure 3.
6. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
Note:
The tamper proof ratchet action will not release the tool until it has been fully closed.
7. Remove the crimped terminal. Inspect for proper
crimp location, and check for insulation closure.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal
to the wire.
2. Remove the crimped terminal from the terminal
locator by pressing down on the wire stop and
gently pulling on the wire. The terminal locator can
be in either position.
3. Visually inspect the crimped terminal for proper
crimp location.
CONDUCTOR OF THE TERMINAL CENTERED
IN CRIMP GRIPS FRONT TO REAR
SEE NOTE
BELOW
SEE NOTE
BELOW
WIRE
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.
Figure 3
Note: The Terminal should be centered in
crimp nests with the outer edges of the crimp
grips flush with the jaws on both sides.
Doc No: ATS-6381932HM Release Date: 03-23-09
Revision: B
Revision Date: 10-04-10
UNCONTROLLED COPY
Page 3 of 8
Tool Kit for Quick Disconnect, Female, Flag 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 fine piece of
equipment it needs cleaning and
lubrication for a maximum service life of
LUBRICATION
trouble free crimping. Use a 30 weight
POINTS
(BOTH SIDES)
automotive (light) oil used at the oil
LIGHT OIL
points, every 5,000 crimps or 3 months,
(EVERY MONTH
shown in Figure 4A or 4B will significantly
OR
enhance the tool life.
5,000 CRIMPS)
4. Wipe excess oil from hand tool,
Figure 4A
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.
Figure 4B
PRELOAD
CHECK POINT
25.4MM
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 the ratchet release lever. See Figure 5.
SETTING WHEEL
ECCENTRIC AXLE
How to Adjust Tool Preload
(See Figure 5)
This hand tool is factory preset to 25-45 LBS.
WRENCH SET
(SOLD
preload. It may be necessary over the life of the
SEPERATELY)
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:
LOCKING
SCREW
HANDLE
GRIP
REMOVED
HANDLE
GRIP
RATCHET
RELEASE LEVER
Figure 5
1. Remove or fold back the handle grip from the handle to expose the eccentric axle and setting wheel.
2. Remove the locking screw with a 2mm hex wrench. The wrench set (63810-0101), is not supplied. It is sold
separately from the hand tool.
3. Turn the eccentric axle and setting wheel with the wrench or pliers Counter-clockwise (CCW) to increase
handle force.
4. Replace the locking screw, aligning the nearest notch in the setting wheel to locking screw.
5. Replace the handle grip.
6. 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
Doc No: ATS-6381932HM Release Date: 03-23-09
Revision: B
Revision Date: 10-04-10
UNCONTROLLED COPY
Page 4 of 8
Tool Kit for Quick Disconnect, Female, Flag Crimp Terminals
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 commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools.
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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.
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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).
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When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.
Doc No: ATS-6381932HM Release Date: 03-23-09
Revision: B
Revision Date: 10-04-10
UNCONTROLLED COPY
Page 5 of 8
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