Molex 63827-9300 Manual de usuario

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals

Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 1 of 7

Revision: B Revision Date: 02-08-21

BELL MOUTH

WIRE

INSULATION

CONTACT GAP

0.00mm - 0.05mm

SEAM

3.75mm 0.20

CONTACT GAP

1.00mm



.20

BEND

DOWN

TWISTIN

ROLLING

BEND

CONDUCTOR

BRUSH

STRIP

LENGTH

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

INSULATION

CRIMP

Application Tooling Specification

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

This tool is IPC/WHMA-A-620 Class 2 compliant

When crimping to AWG type wires, use tool 63811-1500 or 63811-1600

SCOPE

Products: Mini-Fit Sr. Male and Female Terminals crimped to 5mm2and 6mm2wire.

Terminal

Series No.

Terminal

Order No. (3)

Wire Size

Insulation Diameter

Strip Length

IPC/WHMA-A-620 (1)

Terminal (2)

mm²

Construction

In.

42815

42815-0010

42815-0012

42815-0011

42815-0019

37 x 0.45mm

4.00-4.20

.157-.165

3.50-5.30

0.14-0.21

7.50-8.50

0.30-0.36

84 x 0.29mm

65 x 0.32mm

42817

42817-0010

42817-0012

42817-0110

42817-0112

42817-0011

42817-0019

42817-0111

37 x 0.45mm

4.00-4.20

.157-.165

3.50-5.30

0.14-0.21

7.50-8.50

0.30-0.36

84 x 0.29mm

65 x 0.32mm

(1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range

(2) Overall insulation OD specification for terminal.

(3) Reeled terminals: When cutting terminal from strip, cut-off tab not to exceed 0.50mm (.020”)

DEFINITION OF TERMS

TYPE 4E

Order Number

63827-9300

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals

Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 2 of 7

Revision: B Revision Date: 02-08-21

CRIMP SPECIFICATION

Terminal Series No.

Bell Mouth

Conductor Brush

In.

42815

42817

0.20-0.50

.008-.020

3.50-4.50

.140-.180

Terminal Series No.

Bend Up

Bend Down

Twist

Roll

Seam

Degrees Max.

42815

42817

Seam shall not be

open and no wire allowed

out of the crimping area

After crimping, the crimp profiles should measure the following:

Terminal

Series No.

Wire Size

Conductor Crimp

Insulation Crimp

Pull Force

Minimum

Profile

Height (Ref)

Width

(Ref)

Width (Ref)

mm2

In.

Lb.

42815

2.97-3.07

.117-.121

3.95

.155

5.60

0.22

290

3.10-3.30

.122-.130

4.00

.157

5.10

0.20

320

42817

2.97-3.07

.117-.121

3.95

.155

5.60

0.22

290

3.10-3.30

.122-.130

4.00

.157

5.10

0.20

320

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.

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects

as damage can occur to the tool frame or crimping die.

Note

A crimp height chart is provided with this manual as reference only. Because of 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.

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals

Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 3 of 7

Revision: B Revision Date: 02-08-21

TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE

LOCATOR

Figure 3

PRE-STRIPPED

WIRE

TERMINAL

RELEASE THE

LEVER

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. See Figure 1.

Crimping Terminals

1. Select the desired terminal listed in the

preceding charts.

2. Push the wire stop lever on the side of the

hand tool to raise the wire stop up before

inserting the terminal in the hand tool. See

Figure 2.

3. With the wire stop lever pushed in, load the

terminal into the proper nest opening marked

with the wire gauge on the hand tool. See

Figure 2.

4. Next release the wire stop lever, allowing the

wire stop to return to the crimping position.

5. Insert the properly stripped wire through the

terminal and against the wire stop. See Figure

6. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been

completed. Release the handles to open the jaws. See Figure 4.

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

7. Push the wire stop lever in to raise the wire stop up and remove

the crimped terminal from the locator by lifting up and then pulling

the wire out.

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

HANDLES

OPEN

Figure 1

INSERT

TEMINAL

PUSH

LEVER TO

RAISE WIRE

STOP

Figure 2

SQUEEZE

HANDLES

TOGETHER

LEVER

Figure 4

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals

Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 4 of 7

Revision: B Revision Date: 02-08-21

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 hand crimp tool and turn the tool upside down on the back side.

2. Remove the tightening lock nut.

3. Remove the locator assembly from the frame head.

4. To reinstall the new locator, make sure the hand tool is in the open position.

5. Replace the locator assembly into the frame head.

6. Reinstall the tightening lock nut.

Remove and Install Tooling

1. Make sure the tool is in open position before removing or installing tooling.

2. The locator must be removed before removing or installing tooling.

3. Remove the M4 screw that is holding the upper tooling.

4. Remove or install upper tooling through the back side of the tool frame.

5. Install the M4 screw. Make sure the small markings on the front of the hand tool frame

match up. See Figure 5.

6. Follow steps 3-5 for the lower tooling except through the

front side of the tool frame and install the M3 screw. Be

sure the small markings on the lower tooling line up

with upper tooling.

7. Slowly close the tool handles to align upper and lower

tooling together. Tighten the M4 screws and continue

squeezing the tool handles until the hand tool swings

open.

8. Reinstall the locator by following the instructions in the

locator replacement section.

MAINTENANCE

It is recommended that each operator of the tool be made aware of and responsible for the following

maintenance steps: See Figure 6.

1. Un-snap the 2 Snap-On plastic covers (front and back).

2. Remove dust, moisture and other contaminants with a clean

brush or a soft, lint-free cloth.

3. Do not use any abrasive materials that could damage the tool.

4. 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 1,000 crimps or 3

months will significantly enhance the tool life.

5. 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.

6. 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.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY 3 MONTHS

OR 1,000 CRIMPS)

Figure 6

MATCH

UP MARKS

Figure 5

MATCH

UP MARKS

M4 SCREWS

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals

Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 5 of 7

Revision: B Revision Date: 02-08-21

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 using a small flat screwdriver

pressing up on the ratchet release lever in the movable

handle. The handle should be partially closed.

See Figure 7.

HOW TO ADJUST TOOL PRELOAD (SEE FIGURE 8)

This hand tool is factory preset to 210 N (47 pounds) 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. Open the tool by squeezing the handles together

until the ratchet mechanism release, the hand

tool handles will spring open.

2. Remove the M3 screw and the M3 washer.

3. Lift the setting wheel off the axle. Use a small flat

head screwdriver to turn the eccentric axle

counterclockwise (CCW) to increase handle force.

4. To decrease handle force, turn the eccentric axle

clockwise (CW).

5. Line up the setting wheel matching the flat side

with the flat edge of the axle so the wheel notch

will drop onto the roll pin. The numbers will

display higher.

6. Re-install the M3 washer and M3 screw.

7. Re-crimp a new sample and 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, Molex 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.

Figure 7

SMALL

FLAT HEAD

SCREWDRIVER

HANDLES SHOULD BE

PARTIALLY CLOSED

RATCHET

RELEASE LEVER

Figure 8

FLAT HEAD

SCREWDRIVER

M3 x 6 LONG

SCREW

RATCHET

RELEASE

LEVER

RATCHET

RELEASE LEVER

WASHER

SETTING

WHEEL

ECCENTRIC AXLE

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals

Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 6 of 7

Revision: B Revision Date: 02-08-21

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.

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. See the Molex website 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 should be 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 Quick Disconnect, Female Crimp Terminals

Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 7 of 7

Revision: B Revision Date: 02-08-21

Figure 9

M4 x 12 LG SCREW

M4 x 30 LG SCREW

M4 LOCKNUT

M3 x 6 LG SCREW

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63827-9300

Hand Crimp Tool

Figure 9

63827-9375

Locator Assembly

63810-0105

Spring, Ratchet

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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