Molex 63827-0470 User manual

Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals

Doc No: AT -6382704HM Release Date: 09-13-13 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 09-13-13

INSULATION

CRIMP HEIGHT

▲SEE NOTE

BRUSH

STRIP LENGTH

BELL MOUTH

CUT

OFF

TAB

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP HEIGHT

TWISTING

SEAM

WIRE

Application Toolin

Specification Sheet

Modular Crimp Head

Order No. 63827-0470

Hand Crimp Tool

Order No. 63827-0400

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: 1.78mm (.070") Tab Female Crimp Terminals, 16-20 AWG.

Terminal

Series No.

Terminal Order No. Wire Size and Type

(2)

Insulation Diameter

UL1007 or Equivalent Strip Len th

(1)

Reel Form Only

AWG

mm²

In.

35028 35028-1111

0.52

1.75

.069

420-5.00 .165-.197

0.82

2.03

.080

1.31

2.41

.095

(1) Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut

off Tab.

(2) ee crimp specification for the individual Insulation Diameter.

DEFINITION OF TERMS

TYPE 4A

Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals

Doc No: AT -6382704HM Release Date: 09-13-13 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 09-13-13

▲Insulation Crimp Note:

Due to the terminal’s insulation grip design and/or

insulation diameter range, this tool uses “overlap” form

geometry in the insulation punch. This produces an

overlap insulation crimp (A620 – compliant). While the

insulation punch profile may appear “lopsided”, this is

a normal condition for this tool. ee figure to the right.

( ome tools with multiple crimp pockets may not have

the “overlap” profile on all pockets).

CRIMP SPECIFICATIONS:

Terminal Series No.

Bell mouth

●

Conductor

Brush

Bend up Bend Down

Twist Roll

In.

De ree

35028

0.20

0.50

.008

.020

0.00

1.00

0.00

●

Not to exceed above the conductor crimp height.

After crimping, the conductor profiles should measure the following ♦.

Terminal Series No.

Wire Size

♦

Conductor

♦Profile

Crimp Hei ht

Crimp Width

AWG

In.

35028

0.52

1.25

1.32

.049

.051

2.5

2.4

.098

.095

0.82

1.33

1.40

.052

.055

2.5

2.4

.098

.095

1.31

1.40

1.48

.055

.058

2.5

2.4

.095

Terminal

Series No.

Wire Size

Insulation Diameter

Insulation

Pull Force

Minimum

Crimp Hei ht

Crimp Width

In.

Lb.

35028

1.75

.069

2.75

2.95

.108

.116

3.10

3.35

.122

.132

58.6

13.2

2.03

.080

2.95

3.15

.11

.124

3.25

3.35

.128

.132

107.5

24.2

2.41

.095

3.00

3.30

.118

.130

3.25

3.35

.128

.132

127.1

28.6

♦ For 14 AWG and double wire applicators- ee hand tool 63827-0500.

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 ( ee 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 above). 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.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals

Doc No: AT -6382704HM Release Date: 09-13-13 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 09-13-13

WIRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Fi ure 1

Fi ure 2

WIRE

TERMINAL

LOCATOR

INSULATI

PUNCH

SULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR ANVIL

CONDUCTOR

PUNCH

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.

Crimpin Terminals

1. Place the terminal into the correct die profile until the terminal stopped by the locator.

2. Bring the wire stop blade down; make sure the wire stop located behind the conductor grip.

3. Place a pre-striped wire into the terminal until the end of wire touching the wire stop. ee Figure 2.

4. Close the tool until the ratchet releases, the tool handles will then spring open.

5. Carefully remove the crimped terminal.

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

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.

Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals

Doc No: AT -6382704HM Release Date: 09-13-13 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 09-13-13

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

hould 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. ee Figure 6.

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. hould 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.

Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals

Doc No: AT -6382704HM Release Date: 09-13-13 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 09-13-13

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 pecification heet.

ee Chart below for the correct Manual or pecification heet.

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

Fi ure

No.

63827-0470

63816

0000

Hand Crimp Frame ( hort)

N/A

63816

0050

Hand Crimp Frame (Long)

N/A

63816

0200

Battery Power

Tool (110 V)

63816

0600

Battery Power Cri

mp Adapter

63816

0250

Battery Power

Tool (220 V)

63816

0600

Battery Power Crimp Adapter

63816

0100

Air

Tool

63816

0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Fi ure 3

Fi ure 4

Fi ure 5

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for 1.78mm (.070") Tab Female Crimp Terminals

Doc No: AT -6382704HM Release Date: 09-13-13 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 09-13-13

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Fi ure 6

M4 X 14mm

LONG BHCS

PARTS LIST

Item

Order Number

Description

Quantity

63827

Modular

Crimp

Head

1 (

ef)

63816

Hand Crimp

Frame

(Long)

(

ef)

63827

Locator

63816

0001

Locking

63600

0525

Handle pring

63600

0520

Crimping pring

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