Molex 63827-3200 User manual

Hand Crimp Tool for Solder Right In-Board Terminals

Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 1 of 6

Revision: A Revision Date: 0 -05-14

INSULATION CRIMP

BRUSH

STRIP LENGTH

BELL MOUTH

CONDUCTO

CRIMP HEIGHT

SEAM

CUT

OFF TAB

WIRE

Application Tooling

Sp cification Sh t

Modular Crimp H ad

Ord r No. 63827-3270

Hand Crimp Tool

Ord r No. 63827-3200

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.63 16-0100,

accompanied by Air Powered Crimp Adapter (Order No. 63 16-0700).

% Can also be used in the Battery Powered Tool Order No.63 16-0200 (110 V) or 63 16-0250 (220 V),

accompanied by Battery Powered Crimp Adapter (Order No. 63 16-0600).

SCOPE

Products: Solder Right In-Board Terminals, 22-24AWG.

T rminal

S ri s No.

T rminal Ord r No.

Wir Siz

♦

Insulation Diam t r

UL1007 Wir is R comm nd d Strip L ngth

IPC/WHMA

A620 (1)

T rminal

AWG

In.

172677

0100

1.30

–

1.65

0.051

–

0.065

1.40

–

1.60

0.055

–

0.062

5.1

–

5.4

0.20

–

0.21

(1)

To achieve optimum IPC

A620 Class

2 insulation crimps, use this insulation OD.

DEFINITION OF TERMS

TYPE 4A

Hand Crimp Tool for Solder Right In-Board Terminals

Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 2 of 6

Revision: A Revision Date: 0 -05-14

Crimp Sp cification

After crimping, the conductor profiles should measure the following (See Figure 1).

T rminal S ri s No.

Wir Siz

Conductor

Pull Forc Minimum

Profil

Crimp H ight

Crimp

idth

AWG

In.

Lb.

172677

0.74

–

0. 0

0.029

–

0.031

1.45

0.057

35.6

0.6

–

0.74

0.027

–

0.029

1.45

0.057

22.3

S am

shall not be open

and no wire allowed out

of the crimping area

Not s:

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. Variations in tools, terminals, wire stranding, and insulation types

may affect crimp height.

3. This tool is intended for AWG conductors with UL1007 insulation. It may not give a good insulation crimp

support for other insulation styles.

4. Molex does not repair hand tools (see Warranty on page 3). 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. Refer to Molex Quality Crimping

Handbook 63 00-0029 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.

Pr paring T rminals for Crimping

The terminals must be cut from the reel as shown. See Figure 2. The carrier strip hole is used to assist in loading

the terminal in position over the crimp anvils. The carrier strip will help maintain terminal position during crimping

and can be broken off after the crimp is complete.

Crimping T rminals

1. Load the terminal with carrier strip into the proper crimp profile.

Make sure the carrier strip pilot hole fits over the positioning pin.

2. Push the wire stop downward (into the tool frame).

3. Place the properly stripped wire into the open terminal barrel.

Push the wire into the tool until the end of the wire contacts the

wire stop, making sure that all wire strands are inside of the

conductor barrel. See Figures 3 and 4.

4. While holding the wire with one hand, slowly squeeze the tool

handles together to close the tool jaws until the ratchet

mechanism releases. At this point the handles can be released

and will spring open.

5. Remove the crimped terminal and inspect for acceptable crimp

attributes.

Not : The tamper proof ratchet action will not release the tool until it

has been fully closed.

Figur 2

POSITIONING

LOCATOR

Figur 3

TERMINAL

CARRIER STRIP

WIRE STOP

PUCH DOWN

Hand Crimp Tool for Solder Right In-Board Terminals

Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 3 of 6

Revision: A Revision Date: 0 -05-14

Figur 5

WIRE IN CONDUCTOR CRIMP

WIRE STOP

OPEN

Maint nanc

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.

Pull T st Proc dur

Pull testing is to be done with no influence from the

insulation crimp.

Pull testing can be done by the following steps:

1. 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.

2. Load the terminal with the carrier strip into the proper profile make sure the carrier strip pilot hole fits over the

positioning pin on the locator.

3. Do Not close the wire stop.

4. Position a wire form the back side of the hand tool and into the conductor crimp area only. See Figure 5.

5. Carefully crimp the terminal.

6. When pull testing, grip the carrier strip in one jaw and the wire insulation in the other jaw. See Figure 6.

TERMINAL

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL

INSULATION

ANVIL

Figur 4

CONDUCTOR

PUNCH

LOCATOR

WIRE STOP

PULL TESTER

TERMINAL

CLAMP

WIRE

Figur 6

PULL TESTER

WIRE CLAMP

CLAMP TH

CARRIER STRIP

INTO THE TESTER

Hand Crimp Tool for Solder Right In-Board Terminals

Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 4 of 6

Revision: A Revision Date: 0 -05-14

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 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. 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 th Modular Crimp H ad

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 Solder Right In-Board Terminals

Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 5 of 6

Revision: A Revision Date: 0 -05-14

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 Crimp H ad

Ord r No.

Tool

Ord r no.

Tool

D scription

Adapt r

Ord r No.

Adapt r

D scription

Figur

No.

63 27-3270

63 16

0000

Hand Crimp Frame (Short)

N/A

63 16

0050

Hand Crimp Frame (L

ong)

N/A

63 16

0200

Battery Power

Tool (110 V)

63 16

0600

Battery Power Crimp Adapter

63 16

0250

Battery Power

Tool (220 V)

63 16

0600

Battery Power Crimp Adapter

63 16

0100

Air

Tool

63 16

0700

Air Power Crimp Adapter

Applications

for th Modular Crimp H ad

Hand Crimp Tool

Batt ry Pow r d Tool

Air Pow r d Tool

Figur

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for Solder Right In-Board Terminals

Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 6 of 6

Revision: A Revision Date: 0 -05-14

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

Figur 6

M4 X

LONG BHCS

(2)

PARTS LIST

It m

Ord r Numb r

D scription

Quantity

63 27

Modular

Crimp

Head

1 (

ef)

63 16

nd Crimp

Frame

(

Short

)

(

ef)

63 27

Locator

Plate

63 16

0001

Locking

63600

0525

Handle Spring

63600

0520

Crimping Spring

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