Molex 63827-0600 User manual

Hand Crimp Tool for .187 Receptacle Terminal

Doc No: ATS-63827 6HM Release Date: 12-2 -13 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 12-2 -13

TYPE 4A

Application Tooling

Specification Sheet

Modular Cri p Head

Order No. 63827-0670

Hand Cri p Tool

Order No. 63827-0600

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

% A-62 Class 2 compliant as indicated and RoHS compliant

% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816- 1 ,

accompanied by Air Powered Crimp Adapter (Order No. 63816- 7 ).

% Can also be used in the Battery Powered Tool Order No.63816- 2 (11 V) or 63813- 25 (22 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63816- 6 ).

SCOPE

Products: .187 Receptacle Terminal, 2. -3. mm².

Ter inal Series No.

Ter inal Order No.

Wire Size

Insulation Dia eter

Strip Length

(1) Reel

Wire Type

In.

35441 35441-99 2

AVS

2.9

3.1

.114

.122

4.2 -5.

.165-.197

AVSS

2.6

2.7

.1 2

.1 6

AVS

3.6

3.8

.141

.15

(1)

Customer to

cut off terminal from reel: .3 mm (. 12

”) maximum Cut

off Tab.

DEFINITION OF TERMS

This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.

INSULATION

CRIMP

▲SEE NOTE

BRUSH

STRIP

LENGTH

BELL MOUTH

COND.CRIMP

HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

CUT-OFF TAB

SEAM

Hand Crimp Tool for .187 Receptacle Terminal

Doc No: ATS-63827 6HM Release Date: 12-2 -13 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 12-2 -13

▲Insulation Cri p 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 (A62 – compliant). While the

insulation punch profile may appear “lopsided”, this is a

normal condition for this tool. See figure to the right.

CRIMP SPECIFICATION

Ter inal Series No.

Bell outh

Conductor Brush

Bend up Bend down

Twist Roll

In.

Degree (Max.)

35441

. 12

. 24

. 12

After crimping, the crimp profiles should measure the following.

Ter inal Series No

Wire Size

Conductor Cri p

Profile

Height (Ref.)

Width (Ref.)

Type

In.

2.0

3.0

35441

AVS

1.6

1.8

. 63

. 71

125

AVSS

1.6

1.8

. 63

. 71

3.1

AVS

2.2

2.5

. 87

. 98

3.1

.125

Ter inal Order No. Wire Size

Insulation

Cri p







Pull Force Mini u

Height (Ref)

Width (

Max.

)

Type

In.

Lb.

35441

AVS

3.65

144

3.9

.153

196.1

44.1

AVSS

3.65

.144

3.9

.153

196.1

44.1

AVS

4.5

.177

4.5

.177

343.2

77.2



To Achieve IPC

62 Class 2

Crimps, the following over

all wire insulation diameter ranges are recommended:

Profile 2. : 2.6 -3.1 mm (.1 2-.122”) Profile 3. : 3.6 -3.8 mm (.141-.15 ”)

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 638 - 29 for additional information on crimping and crimp testing.

6. Molex does not certify crimp hand tools.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for .187 Receptacle Terminal

Doc No: ATS-63827 6HM Release Date: 12-2 -13 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 12-2 -13

Figure 2

WIRE

TERMINAL

LOCATOR

INSULATI

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR ANVIL

CONDUCTOR

PUNCH

IRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Figure 1

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.

Cri ping Ter inals

1. Lift the wire stop blade up.

2. Insert the terminal fully into the correct profile until the terminal is fully seated and stops.

3. Bring down the wire stop blade.

4. Slide the pre-stripped wire into the wire stop blade. See Figure 1. Be sure to hold the wire in place until the

terminal is fully crimped. See Figure 2.

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

6. Lift the wire stop blade up if it is still in down position.

7. 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.

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 3 weight

automotive oil) used at the oil points, every 5, 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.

Hand Crimp Tool for .187 Receptacle Terminal

Doc No: ATS-63827 6HM Release Date: 12-2 -13 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 12-2 -13

Miscri ps or Ja s

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 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 3

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.

Applications for the Modular Cri p 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.

Hand Crimp Tool for .187 Receptacle Terminal

Doc No: ATS-63827 6HM Release Date: 12-2 -13 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 12-2 -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

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

Modular Cri p Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63827- 67

63816

Hand Crimp Frame (Short)

N/A

63816

Hand Crimp Frame (Long)

N/A

63816

Battery Power

Tool (11 V)

63816

Battery Power Crimp Adapter

63816

Battery Power

Tool (22 V)

63816

Battery Power Crimp Adapter

63816

Air

Tool

63816

Air Power Crimp Adapter

Applications for the Modu

lar Cri p Head

Hand Cri p Tool

Battery Powered Tool

Air Powered Tool

Figure

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for .187 Receptacle Terminal

Doc No: ATS-63827 6HM Release Date: 12-2 -13 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 12-2 -13

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figure 6

M4 X 14

LONG BHCS

PARTS LIST

Ite

Order Nu ber

Description

Quantity

63827

Modular

Crimp

Head

1 (

ef)

63816

Hand Crimp

Fra

(Long)

(

ef)

63827

Locator

63816

Locking

636

525

Handle Spring

636

Crimping Spring

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

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