Molex 63827-5470 Manual de usuario

Hand Crimp Tool for ULTRA-FIT Crimp Terminals

Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 01-30-15

TYPE 4A

ROLLING

INSULATION

CRIMP HEIGHT

BRUSH

STRIP LENGTH

BELL MOUTH

CONDUCTOR

CRIMP HEIGHT

BEND DOWN

BEND UP

TWISTING

SEAM

CUT-OFF

TAB

WIRE

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63827-5470

Hand Crimp Tool

Order No. 63827-5400

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

Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).

Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63816-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).

SCOPE

Products: ULTRA-FIT Crimp Terminals, 20-22 AWG (UL1061) wires.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

UL1061 Wire is Recommended

Strip Length

AWG

mm²

Type

In.

172253

172253-3111

172253-3112

20-22

---

UL1061

1.22-1.44

.048-.057

3.50-4.00

.138-.158

172253-3123

DEFINITION OF TERMS

Hand Crimp Tool for ULTRA-FIT Crimp Terminals

Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 01-30-15

CRIMP SPECIFICATION

Terminal Series No.

Bell mouth

Cut-off Tab Max (Ref)

Conductor Brush

In.

172253

0.30-0.50

.012-.020

0.20

.008

0.00-1.00

.000-.039

Terminal Series No.

Bend up Bend down

Twist Roll

Seam

Seam shall not be open

and no wire allowed out

of the crimping area

Degree (Max)

172253

After crimping, the conductor profile should measure the following.

Terminal Series No.

Wire Size

Conductor

Profile

Crimp Height

Crimp Width (Max.)

AWG

mm2

In.

172253

---

0.82-0.92

.032-.036

1.60-1.70

.063-.067

---

0.73-0.83

.029-.033

1.60-1.70

.063-.067

Terminal Series No.

Wire Size

Insulation

Pull Force Minimum

Crimp Height (Max.)

Crimp Width (Max.)

AWG

mm2

In.

Lb.

172253

---

1.90

.075

1.95

.077

57.9

13.0

---

1.70

.067

1.65

.065

35.6

8.0

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.

Notes:

1. This tool should only be used for the terminals and wire gauges specified on this sheet.

2. This tool is not adjustable for crimp height; however crimp force is adjustable (See instructions above).

Variations in tools, terminals, wire stranding and insulation types may affect crimp height.

3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all

insulation sizes.

4. Molex does not repair hand tools (see warranty). The replacement parts listed are the only parts available for

repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no

influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips

on the terminal do not grip the wire insulation or the conductor. Refer to Molex Quality Crimping

Handbook 63800-0029 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

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.

Hand Crimp Tool for ULTRA-FIT Crimp Terminals

Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 01-30-15

WIRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Figure 2

Figure 3

WIRE

TERMINAL

LOCATOR

INSULATION

PUNCH

INSULATION ANVIL

WIRE STOP

BLADE

CONDUCTOR ANVIL

CONDUCTOR

PUNCH

1. With the hand tool in the open position, pivot the

terminal locator open by pulling up on the locator knob

and lift the wire stop blade up. See Figure 1.

2. Insert the terminal into the correct profile until the

terminal is fully seated and stops.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade. Make sure the wire

stop blade is fully seated on the terminal behind the

conductor grip section.

5. Slide the pre-stripped wire into the terminal; make sure

to aim the wire brush towards the tip point on the wire

stop blade. See Figure 2. Align the wire so that it is

parallel and sitting into the terminal. Maintain a light

and constant pressure on the wire that is seated in the terminal at all times. (Do not let go of the wire.)

Be sure to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases.

7. Lift the wire stop blade up.

8. Carefully remove the crimped terminal.

Note: To maintain good brush control and a consistent

bell mouth the crimping instructions must be followed.

Terminal Locator Replacement

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Place the new locator, (See Chart on page 2), on the hand tool. Install the M4 BHCS. See Figure 4.

2. Tighten the screw enough to hold the locator. Make sure the locator can still float freely with hand pressure.

3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then

gently pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct position. See Figure 5.

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR

OPEN

Figure 1

HAND TOOL

OPEN

WIRE

STOP

BLADE

Hand Crimp Tool for ULTRA-FIT Crimp Terminals

Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 01-30-15

5. Gently pivot the locator open without disturbing the location.

6. Hold the locator firmly in place and slowly tighten the M4 BHCS.

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.

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 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 or 3 months,

will significantly enhance the tool life.

4. 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.

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.

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 lifting the ratchet release lever.

See Figure 9.

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: Repetitive use of this tool should be avoided.

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.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

M4 BHCS

PIVOT LOCATOR

Figure 4

INCORRECT

Figure 5

CORRECT

INCORRECT

Hand Crimp Tool for ULTRA-FIT Crimp Terminals

Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 01-30-15

MODULAR

CRIMP

HEAD

BATTERY

POWER

CRIMP

ADAPTER

LOCKING

PINS

LOCKING PINS

BATTERY

POWERED

TOOL

AIR

POWER

TOOL

MODULAR

CRIMP HEAD

LOCKING

PINS

LOCKING

PINS

AIR POWER

CRIMP

ADAPTER

Applications for the Modular Crimp Head

WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction

and without first reading and understanding the instructions in the proper Manual or Specification Sheet.

See Chart below for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the

power by unplugging or turn off the Actuator from its power source.

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.

The chart below shows all applications for this Modular Crimp Head.

Modular Crimp Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure No.

63827-5470

63816-0000

Hand Crimp Frame (Short)

N/A

63816-0050

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool

63816-0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure 6

Figure 7

Figure 8

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for ULTRA-FIT Crimp Terminals

Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 01-30-15

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 9

M4 X 6mm

LONG BHCS

PARTS LIST

Item

Order Number

Description

Quantity

63827-5470

Modular Crimp Head

63816-0000

Hand Crimp Frame (Short)

63827-5475

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

Visit our Web site at http://www.molex.com

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