molex 78172 Series User manual

Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminal
Doc No: ATS-6381948000 Relea e Date: 08-17-09 UNCONTROLLED COPY Page 1 of 6
Revi ion: A Revi ion Date: 08-17-09
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP TOOL
SPECIFICATION SHEET
Order No. 63819 4800
FEATURES
% A full cycle ratcheting hand tool en ure complete crimp
% Thi tool i de igned to be u ed with reeled product due to the mall ize of the connector
% Thi tool i de igned for prototype work only and i not de igned for production
% The reeled product mu t be cut into 5-inch trip to be proce ed in thi hand tool
% Thi tool i IPC/WHMA A-620 Cla 2 compliant a indicated
% Thi tool i RoHS compliant, however RoHS compliant i not required
SCOPE
Product : 1.20mm (.047”) Pitch Pico-EZmate™ Wire-to-Board Crimp Terminal, 28 AWG.
Insulation Diameter
Wire Size IPC/WHMA A620 Terminal



 Strip Length
Terminal
Series No.
Terminal Order No.
Reel Form Only AWG
mm² mm In. mm In. mm In.
78172-0410
78172 78172-0411 28 0.08 0.55-0.70 .022-.028 0.55-0.70 .022-.028 0.90-1.30 .035-.051
To achieve optimum IPC-A620 in ulation crimp , u e thi in ulation OD range.
Overall in ulation OD pecification for terminal.
Cu tomer to cut off terminal from reel: 0.05mm (.002”) maximum Cut-off Tab.
DEFINITION OF TERMS
The above terminal drawing i a generic terminal repre entation. It i not an image of a terminal li ted in the
cope.
TYPE 7

Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminal
Doc No: ATS-6381948000 Relea e Date: 08-17-09 UNCONTROLLED COPY Page 2 of 6
Revi ion: A Revi ion Date: 08-17-09
INSULATION CRIMP FORM
Thi crimp terminal i de igned for miniaturization; therefore, each dimen ion of in ulation crimp portion appear
mall a compared to the terminal material thickne . In order to avoid in ulation piercing the crimp form by the
in ulation barrel, coining i provided in ide of the in ulation barrel. For thi rea on, variou crimp form will occur at
the tip of the in ulation crimp barrel hown in the figure below.
The e crimp form maybe changed completely by a mall change in the wire, in ulation punch, or terminal.
The e crimp form are ati factory for original function of the in ulation crimp portion and it i confirmed that all of
the e form below are acceptable in ulation crimp .
CONDITIONS:
After crimping, the conductor profile hould mea ure the following.
Conductor Crimp (Ref) Insulation Crimp (Ref)
Wire Size Height Width Height Width
Pull Force
Minimum
Terminal
Series No
AWG mm2 mm In. mm In. mm In. mm In. N Lb.
78172 28 0.08 0.44-0.48 .017-.019 0.85 .033 0.77 .030 0.85 .033 10.0 2.25
OPERATION
CAUTION: In tall only Molex terminal li ted above with thi tool. Do not crimp hardened object a
damage can occur to the tool or die.
Open the tool by queezing the handle together, at the end of the clo ing troke, the ratchet mechani m will
relea e the handle , and the hand tool will pring open.
Crimping Terminals
1. Select the de ired terminal li ted in the preceding chart .
2. Cut a trip of the terminal approximately 5.0” off the reel. Po ition the terminal trip into the lot of the carrier
guide with terminal facing forward.
3. Pu h the trip in until it lock into the (2) detent in the carrier guide and a terminal i centered with the punch
ne t. See Figure 1.
4. Partially clo e the jaw of the hand tool by queezing the handle until you hear the fi t click of the ratchet.
5. From the top of the hand tool in ert the pre- tripped wire into the terminal.
6. Compre the terminal by queezing the tool handle until the ratchet mechani m cycle ha been completed.
Relea e handle to open the jaw .

Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminal
Doc No: ATS-6381948000 Relea e Date: 08-17-09 UNCONTROLLED COPY Page 3 of 6
Revi ion: A Revi ion Date: 08-17-09
Note: The tamper proof ratchet action will not relea e the tool until it ha been fully clo ed.
7. Lift up the crimped terminal from the
terminal locator.
8. Vi ually in pect the crimped terminal
for proper crimp location.
9. If crimping more wire advance the
terminal trip by (1) detent until the
terminal i centered with the punch
ne t.
10. Repeat thi procedure until all the
de ired terminal are crimped on the
trip.
Maintenance
It i recommended that each operator of
the tool be made aware of, and re pon ible
for, the following maintenance tep :
1. Remove the pla tic handle from the metal tool
frame by removing the crew and remove du t,
moi ture, and other contaminant with a clean bru h,
or oft, lint free cloth.
2. Do not u e any abra ive material that could
damage the tool.
3. Make certain all pin ; pivot point and bearing
urface are protected with a thin coat of high quality
machine oil. Do not oil exce ively. The tool wa
engineered for durability but like any fine piece of
equipment it need cleaning and lubrication for a
maximum ervice life of trouble free crimping. Light
oil u ed at the pivot point every 5,000 crimp or 3
month , will ignificantly enhance the tool life.
4. Wipe exce oil from hand tool, particularly from
crimping area.
5. When tool i not in u e, keep the handle clo ed to
prevent object from becoming lodged in the
crimping die , and tore the tool in a clean, dry area.
Miscrimps or Jams
Should thi tool ever become tuck or jammed in a partially clo ed po ition, Do Not force the handle open or
clo ed. The tool will open ea ily by pre ing the ratchet relea e lever up. See Figure 2.
SLIDE WIRE
INTO THE
PUNCH NEST
Figure 1
LOCKS IN THE
TERMINAL STRIP
SLIDE TERMINAL
STRIP INTO THE
CARRIER GUIDE
CRIMP TOOL OPEN
WIRE
RATCHET
RELEASE LEVER
Figure 2

Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminal
Doc No: ATS-6381948000 Relea e Date: 08-17-09 UNCONTROLLED COPY Page 4 of 6
Revi ion: A Revi ion Date: 08-17-09
NUMBERED ADJUSTMENT
WHEEL
Figure
3
TURN CLOCKWISE (CW) OR
COUNTER CLOCKWISE (CCW)
TO ADJUST THE PRE LOAD
TURN WITH A SMALL
SCREW DRIVER
REMOVE THE LOCKING 2MM SCREW
How to Adjust Tool Preload
It may be nece ary over the life of the tool to adju t tool handle preload force. Li ted below are the tep
required to adju t the crimping force of the hand tool to obtain proper crimp condition :
1. Remove the 2mm locking crew from the numbered adju ting wheel u ing a crew driver. See Figure 3.
2. U ing the ame crew driver turn the adju tment wheel to the next highe t number.
Note: The uneven number are in clockwi e (CW) direction and the even number are counter clockwi e
(CCW).
3. Example: If the preload i et at number 5, then to increa e the preload, turn the adju tment wheel until the 6th
po ition i located over the 2mm locking crew tapped hole. If it i nece ary to move to the 7th po ition, then
the adju tment wheel hould be turned counter clockwi e (CCW) until the 7th po ition i over the 2mm locking
crew tapped hole.
4. Replace the 2mm locking crew, aligning the neare t notch in the etting wheel to locking crew.
5. Check the crimp pecification and conduct a pull te t after tool handle preload force i adju ted. Repeat
the e tep until the de ired re ult i obtained.
Warranty
Thi tool i for electrical terminal crimping purpo e only. Thi tool i made of the be t quality material . All vital
component are long life te ted. All tool are warranted to be free of manufacturing defect for a period of 30
day . Should uch a defect occur, we will repair or exchange the tool free of charge. Thi repair or exchange will
not be applicable to altered, mi u ed, or damaged tool . Thi tool i de igned for hand u e only. Any clamping,
fixturing, or u e of handle exten ion void thi warranty.
CAUTION: Molex crimp pecification are valid only when u ed with Molex terminal and tooling.

Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminal
Doc No: ATS-6381948000 Relea e Date: 08-17-09 UNCONTROLLED COPY Page 5 of 6
Revi ion: A Revi ion Date: 08-17-09
CAUTIONS:
1. Manually powered hand tool are intended for low volume, prototyping, or field repair. Thi tool i NOT
intended for production u e. Repetitive u e of thi tool hould be avoided.
2. In ulated rubber handle are not protection again t electrical hock.
3. Wear eye protection at all time .
4. U e only the Molex terminal pecified for crimping with thi tool.
Certification
Molex doe not certify or re-certify hand tool but rather upplie the following guideline for cu tomer to re-certify
hand tool .
% Thi tool i qualified to pull force only. To re-certify, crimp a terminal to a wire, which ha been tripped
12.7mm (1/2”) long, o there i no crimping of the in ulation. Pull the terminal and wire at a rate no fa ter than
25mm (1.00”) per minute. See the Molex web ite for the Quality Crimp Handbook for more information on pull
te ting.
% If the tool doe not meet minimum pull force value , handle preload hould be increa ed and the pull te t rerun,
(See How To Adju t Preload).
% When the hand tool i no longer capable of achieving minimum pull force, it hould be taken out of ervice and
replaced.

Hand Crimp Tool 1.20mm (.047”) Pitch Pico-EZmate™ Crimp Terminal
Doc No: ATS-6381948000 Relea e Date: 08-17-09 UNCONTROLLED COPY Page 6 of 6
Revi ion: A Revi ion Date: 08-17-09
3
Figure
4
1
2
4
PARTS LIST
Item Order No Description Quantity
REF 63819 4800 Hand Crimp Tool Figure 4
1 63819-4870 Tool Kit 1
2 11-11-0320 Spring (Ratchet) 1
3 63600-0479 Spring (Main) 1
4 69008-0972 Adju ter Wheel 1
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