Molex 63827-7900 Manual de usuario

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.

Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 02-03-15

INSULATION CRIMP

BRUSH

STRIP LENGTH

CONDUCTOR

CRIMP HEIGHT

CUT-OFF TAB

SEAM

BELL MOUTH

WIRE

CUT-OFF TAB

HAND CRIMP

TOOL

Application Tooling

Specification Sheet

Order No. 63827-7900

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

Dies and Locator from this tool can be used in the Battery Powered Tool Order No.63816-0200 (110 V) or

63816-0250 (220 V), with the use of the 63816-0800 Crimp Head

Many different tool kits can be used with a single Battery Powered Crimp Tool

This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: 6.35mm Slip-On Receptacle, 22 - 20 AWG.

Terminal Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

Reel

AWG

mm²

In.

35725

35725-3800

22-20

0.35-0.50

2.6 max

.102 max

4.80-5.20

.157-.205

35725-3801

35725-3810

Customer to cut off terminal from reel: Cut tabs flush with terminal at both ends.

DEFINITION OF TERMS

TYPE 4D

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.

Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 02-03-15

CONDITIONS:

After crimping, the conductor profiles should measure the following. See Notes below.

Terminal Series No.

Wire Size

Conductor Crimp

Profile

Height (Ref.)

Width (Ref.)

AWG

mm2

In.

35725

0.35

1.10-1.30

.043-.051

2.10-2.30

.083-.091

0.50

1.20-1.40

.047-.055

2.10-2.30

.083-.091

Terminal Series No.

Wire Size

Insulation Crimp

Pull Force Minimum

Width (Ref.)

AWG

mm2

In.

Lb.

35725

0.35

2.80-3.00

.110-.118

58.8

13.2

0.50

2.80-3.00

.110-.118

78.4

17.6

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 document 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.

OPERATION

CAUTION: Crimp only the Molex

terminals listed in the scope for this tool.

Do not crimp hardened objects as

damage can occur to the tool frame

and/or crimp dies.

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.

Crimping Terminals

1. Select the desired terminal listed in the preceding charts.

2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button

on the back of the hand tool to bring the locator forward through the tooling. See Figure 2.

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.

Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 02-03-15

RELEASE

LOCATOR BUTTON

TERMINAL

Figure 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

PRE-STRIPPED WIRE

TERMINAL

WIRE AGAINST THE

WIRE STOP

Figure 5

TERMINAL

WIRE

WIRE STOP IS PART

OF THE LOCATOR

3. While holding the locator button in, load the terminal into the proper nest

opening in the locator based on the wire gauge or terminal type

markings on the hand tooling. See Figure 3.

4. Release the locator button, allowing the locator to return to the crimping

position.

5. Close the tool handle until the first ratchet position engages. See

Figure 4.

6. Insert the properly stripped wire through the terminal and against the

wire stop. See Figure 5.

7. Crimp the terminal by squeezing the tool handles until the ratchet

mechanism cycle has been completed. Release the handles to open

the jaws.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

8. Remove the crimped terminal from the terminal locator by pulling

on the wire.

9. Visually inspect the crimped terminal for proper crimp location.

10. On some large O.D. wires, it may not be possible to insert the wire

with the tool partially closed. Those wires should be inserted with

the hand tool in the open position. Insert the wire above the

terminal in the punch and against the wire stop then close the tool.

See Figure 6.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

TERMINAL

Figure 6

WIRE

STOP

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.

Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 02-03-15

Figure 9

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT

BACK

Figure 8

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.

2. Squeeze gently on the lower area shown in

Figure 7A with your thumb and index finger.

The lower tabs of the locator should

disengage from the hand tool.

3. Lift and pull away from the hand tool. The

top locator hooks should slip out of the top

slots easily. See Figure 7A.

4. To reinstall the new locator, make sure the

hand tool is in the open position.

5. Press the red insert down as far as it will go

as shown in Figure 7B.

6. Holding onto the lower part of the locator

with your thumb and index finger, insert the locators top hooks (2) into the hand tool top slots.

7. Rotate the locator down and press the lower tabs

into the two bottom slots of the hand tool. To

secure the locator into place, the lower tabs must

snap into place on the hand tool frame.

Right or Left Hand Operation

This hand tool has an added feature that can be

converted from a right handed application to a left

handed application. It is necessary to reverse the

tooling if using the left handed application along with the locator. Follow the steps below:

1. The locator must be removed before reversing the

tooling.

2. Remove the M3 BHCS which is holding the upper

tooling.

3. Flip the upper tooling to the opposite side and

replace the M3 BHCS. Make sure the small

markings on the front and back of the hand tool

frame, match up and are on the outside of the

hand tool frame. See Figure 8 and 9.

4. Do the same thing with the lower tooling and

tighten the M3 screws. Be sure the small

markings line up.

5. Reinstall the locator by following the Instructions

in the locator replacement section.

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figure 7B

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.

Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 02-03-15

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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 pressing up on the ratchet release

lever in the movable handle. See Figure 11.

How to Adjust Tool Preload

(See Figure 12)

This hand tool is factory preset to 25-45

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:

1. Hold the hand tool in the palm of your

hand as shown in Figure 12. Using

the index finger squeeze the link

towards the top of the hand tool frame.

This will release the preload

adjustment wheel.

2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.

To decrease handle force rotate the setting wheel clockwise (CW).

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

RATCHET RELEASE

LEVER

Figure 11

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.

Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 02-03-15

3. Release the link to lock the setting wheel in place.

4. 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.

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 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 web site for the Quality Crimp Handbook for more information on pull

testing.

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).

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

replaced.

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.

Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 02-03-15

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63827-7900

Hand Crimp Tool

Figure 13

63827-7975

Locator Assembly

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

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

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