Molex 63827-1600 Manual de usuario

Hand Crimp Tool Super-Sabre Crimp Terminals

Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 1 of 7

Revision: D Revision Date: 09-23-21

Application Tooling Specification

FEATURES

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 63816-0270 (110 V) or the 63816-0280 (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: Super-Sabre Male and Female Crimp Terminals, 10 AWG.

Terminal Series No.

Terminal Order No.

Wire Size

Insulation Diameter (1)

Strip Length

Reel

AWG

mm²

In.

171825

171825-0100

171825-8100

—

4.60 Ref.

.181 Ref.

7.9-8.3

0.31-0.33

171826

171826-0100

171826-8100

171826-0200

171826-8200

Customer to cut off terminal from reel: 0.50mm (.020”) maximum cut-off tab.

(1)This terminal series does not have an Insulation grip

DEFINITION OF TERMS

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWIST

ROLL

BEND

DOWN

WIRE

171825 Series

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWIST

ROLL

BEND

DOWN

WIRE

171826 Series

Order Number

63827-1600

TYPE 4C

Hand Crimp Tool Super-Sabre Crimp Terminals

Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 2 of 7

Revision: D Revision Date: 09-23-21

CONDITIONS

After crimping, the conductor profiles should measure the following (see notes below):

Terminal Series No.

Wire Size

Conductor Crimp

Pull Force Minimum

Profile

Height

Conductor Width

AWG

mm2

In.

Lb.

171825

—

2.33-2.43

.092-.096

3.60-3.80

.142-.150

356

171826

2.62-2.72

.103-.107

4.30-4.50

.169-.177

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 performed 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:

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.

Locator Installation and Removal

Follow the steps below to install or replace the locator.

See Figure 2.

To Install the Locator

1. Position the locator with the hole over the brass pivot shaft

and snap it into place.

To Remove the Locator

1. Open the hand crimp tool.

2. Swing the existing locator open and away from the hand

tool.

3. Firmly press down on the brass pivot shaft with your thumb

while pulling the locator up. Slip the locator off the top of the

brass pivot shaft.

ANVIL

POWER

CRIMP

HEAD

Figure 1

PUNCH

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

Hand Crimp Tool Super-Sabre Crimp Terminals

Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 3 of 7

Revision: D Revision Date: 09-23-21

Figure 4

WIRE IN

TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

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.

Crimping Terminals

Swing the terminal locator against the crimp tool and

turn the lock up to lock the locator. Terminals can be

loaded easily while the locator is against the crimp tool

and locked. The spring-loaded locator needs to be in

the up position for terminals to load easily. See Figure

1. To raise the wire stop, press the tab on the wire

stop as shown in Figure 3. Insert the proper

terminal into the nest opening and release the

wire stop to lower it. When choosing the nest

opening, make sure it will correspond with the A

or B profile on the hand tool.

2. Insert the proper pre-striped wire over the terminal. Gently touch the wire stop with the end

of the wire. See Figures 4 and 5.

3. 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.

4. Remove the crimped terminal from the terminal locator by pressing the tab on the wire stop

and gently pulling on the wire.

5. Visually inspect the crimped terminal for proper crimp location and crimp height.

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.

HANDLE OPEN

LOCK IN UP RIGHT

POSITION

LOCATOR

CLOSED

Figure 3

MALE OR

FEMALE

TERMINAL

PUSH HERE

TO OPEN

WIRE STOP

LOCATOR

ANVIL

TERMINAL

WIRE

PUNCH

WIRE AGAINST STOP

Figure 5

WIRE STOP

Hand Crimp Tool Super-Sabre Crimp Terminals

Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 4 of 7

Revision: D Revision Date: 09-23-21

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.

3. Make certain all pins, pivot points and

bearing surfaces in the tool head are

protected with a thin coat of high-

quality machine oil. Do not oil

excessively. This tool was engineered

for durability, but like any fine piece of

equipment, it needs cleaning and

lubrication for a maximum service life

of trouble-free crimping. The use of a

light oil such as 30 weight automotive

oil every 5,000 crimps or monthly will

significantly enhance the tool life and ensure a stable calibration. See Figures 6A or 6B for

lubrication points.

4. Store the tool in a clean and dry area when it is not in use.

Miscrimps or Jams for Hand Crimp Tools Only (See Figure 9)

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 rotating the small slotted screw

marked with an arrow. See Figure 9.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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, Molex will repair or

exchange the tool kit free of charge. This repair or exchange will not be applicable to altered,

misused or damaged tools.

Handheld crimping tools are intended for low volume, prototyping or repair requirements only.

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 use 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.

CAUTION: Repetitive use of this tool should be avoided.

Figure 6B

LUBRICATION POINTS

(BOTH SIDES) LIGHT

OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 6A

Hand Crimp Tool Super-Sabre Crimp Terminals

Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 5 of 7

Revision: D Revision Date: 09-23-21

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.

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 website for the Quality Crimp

Handbook for more information on pull testing.

When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of

service and replaced.

This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

The chart below shows all applications for this tool kit:

Tool Kit Order No.

Tool Order no.

Tool Description

Power Head

Order No.

Adapter

Description

Figure No.

63827-1670

63810-1050

Hand Crimp Frame (Short)

—

63810-1000

Hand Crimp Frame (Long)

—

63816-0270

Battery Power Tool (110 V)

63816-0300

Power Crimp Head

63816-0280

Battery Power Tool (220 V)

63816-0300

Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure 7

Figure 8

WARNING: NEVER operate, service or install tool kits or adjust the power crimp head without proper

instruction and without first reading and understanding the instructions in the proper manual or

specification sheet. See chart above for the correct manual or specification sheet.

WARNING: NEVER install tooling or service this tool while it is connected to any power source. Make

sure the power is turned off.

CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe

injury.

CAUTION: Wear safety glasses when operating or serving this tool.

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

Hand Crimp Tool Super-Sabre Crimp Terminals

Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 6 of 7

Revision: D Revision Date: 09-23-21

RATCHET

RELEASE SCREW

Figure 9

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810-1000

Hand Crimp Frame (Long)

63827-1670

Tool Kit with Locator

63827-1673

Locator Base

63827-1675

Locator

REF

Hand Crimp Tool Super-Sabre Crimp Terminals

Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 7 of 7

Revision: D Revision Date: 09-23-21

Figure 10

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item

Order Number

Engineering No.

Description

Quantity

63816-0300

Power Crimp Head

63827-1670

Tool Kit

Application Tooling Support

Phone: (402) 458-TOOL (8665)

E-Mail: [email protected]

Website: www.molex.com/applicationtooling

Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other

trademarks listed herein belong to their respective owners.

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