Molex 63827-5000 Manuel utilisateur

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal

Doc No: 638275000 Release Date: 04-27-15

UNCONTROLLED COPY

Page 1 of 7

Revision: Revision Date: 05-24-17

INSULATION

CRIMP

BRUSH

STRIP LENGTH

BELL MOUTH

CONDUCTOR

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

WIRE

TWISTING

CUT

OFF

TAB

SEAM

HAND CRIMP

TOOL

Application Tooling

Sp cification Sh t

Ord r No. 63827-5000

FEATURES



A full cycle ratcheting hand tool ensures complete crimps



Ergonomic soft grip handles for comfortable crimping



A precision, user-friendly terminal locator holds terminals in the proper crimping position



Right and Left handed applications



Dies and Locator from this tool can be used in the attery-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 attery-Powered Crimp Tool



This tool is RoHS compliant; however, RoHS compliance is not required

SCOPE

Products: 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal, 28 AWG.

T rminal S ri s No.

T rminal Ord r No.

R l Form Only (1)

Wir Siz

Insulation Diam t r

(Max)

Strip L ngth

AWG

mm²

In.

104505

8003

0.089

0.97

.38

1.10

1.40

.043

.055

(

)

Customer to cut off terminal from reel: 0.10mm (.004”) maximum Cut

ff Tab.

DEFINITION OF TERMS

TYPE 4D

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal

Doc No: 638275000 Release Date: 04-27-15

UNCONTROLLED COPY

Page 2 of 7

Revision: Revision Date: 05-24-17

RELEASE

LOCATOR

BUTTON

TERMINAL

Figur 3

LOCATOR

PUSHED

THROUGH

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

CONDITIONS

After crimping, the conductor profiles should measure the following:

T rminal

S ri s No.

Wir Siz

Conductor Crimp

Insulation Crimp

(R f)

Pull Forc

Minimum Profil

H ight

Width (R f.)

H ight

Width

AWG

In.

Lb.

104505

0.089

0.90

.035

9.8

2.20

Tool Qualification Not s

1. Pull force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

Not :

A crimp height chart is provided with this document

as reference only. ecause 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.

OPERATION

CAUTION: Crimp only the Molex terminals

listed in the scope for this tool. Do not crimp

hardened objects because damage can occur to the tool frame 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 T rminals

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.

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.

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figur 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figur 1

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal

Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 3 of 7

Revision: Revision Date: 05-24-17

PARTIALLY

CLOSE HANDLE

TOOLING PARTIALLY

CLOSED

Figur 4

FIRST RATCHET

POSITION

OPEN

POSITION

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 above the terminal and against the locator.

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.

Not : 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 the proper crimp location.

Locator R plac m nt

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

6A 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 6A.

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 6 .

6. Holding onto the lower part of the locator with your

thumb and index finger, insert the locator’s top hooks (2) into the hand tool’s 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.

Figur 5

LOCATOR

TERMINAL WIRE AGAINST THE LOCATOR

TERMINAL

PRE

STRIPPED

WIRE

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figur 6A

TOP HOOKS

TOP SLOTS OF

HAND TOOL

LOWER TABS

MAKE SURE

CENTER OF

LOCATOR

IS IN THE

DOWN POSITION

igur 6

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal

Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 4 of 7

Revision: Revision Date: 05-24-17

Figur 7

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT

BACK

Figur 8

Right or L ft Hand Op ration

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 HCS, which is holding the upper

tooling.

3. Flip the upper tooling to the opposite side, and

replace the M3 HCS. 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 Figures 7 and 8.

4. Do the same thing with the lower tooling, and tighten

the M3 screws. e sure the small markings line up.

5. Reinstall the locator by following the instructions in the

locator replacement section.

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 a

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 the 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.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figur 9

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal

Doc No: 638275000 Release Date: 04-27-15

UNCONTROLLED COPY

Page 5 of 7

Revision: Revision Date: 05-24-17

Figur 1

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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 10.

How to Adjust Tool Pr load

(S Figur 11)

This hand tool is factory preset to 25-45 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. Hold the hand tool in the palm of your

hand as shown in Figure 10. Using

your index finger, squeeze the link

toward the top of the hand tool frame.

This will release the preload

adjustment wheel.

2. Rotate the setting wheel

counterclockwise (CCW) to increase

handle force. The numbers will display

higher. To decrease handle force,

rotate the setting wheel clockwise

(CW).

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, 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.

RATCHET RELEASE

LEVER

Figur 10

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal

Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 6 of 7

Revision: Revision Date: 05-24-17

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.

C rtification

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 that has been stripped 12.7mm

(.50”) long so that 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 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 for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal

Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 7 of 7

Revision: Revision Date: 05-24-17

PARTS LIST

It m Numb r

Ord r Numb r

D scription

Quantity

REF

638

Hand Crimp Tool

Figure 13

638

Locator Assembly

63810

0104

Spring, Return

63810

0105

Spring, Ratchet

Application Tooling Support

Phon : (402) 458-TOOL (8665)

E-Mail: [email protected]

W bsit : 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.

RATCHET

RELEASE LEVER

Figur 13

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