Molex 63827-6070 Manuale utente

Hand Crimp Tool for Nano-Fit™Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 10-22-14

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

INSULATION CRIMP

Application Tooling

Specification Sheet

Modular Crimp Head

Order No. 63827-6070

Hand Crimp Tool

Order No. 63827-6000

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-620 Class 2 compliant as indicated and RoHS compliant

Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,

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: Nano-Fit™Receptacle Terminals, 24AWG and 26 AWG, UL1061 and UL1007 Insulations.

Terminal

Series No.

Terminal

Order No.

Wire Size

Insulation Diameter

Strip

Length

IPC/WHMA-A620 (1)

Terminal (2)

AWG

mm²

In.

105300

105300-1100

105300-1200

24-26

1.10-1.40

0.043-0.055

0.99-1.40

0.039-0.055

2.5-3.5

0.098-0.138

105300-1300

(1) To achieve optimum IPC-A620 Class 2 insulation crimps, use this insulation OD.

(2) Overall insulation OD specification for terminal.

DEFINITION OF TERMS

TYPE 4A

Hand Crimp Tool for Nano-Fit™Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 10-22-14

CRIMP SPECIFICATION

Terminal Series No.

Bell mouth

Cut-off Tab Maximum

Conductor Brush

In.

105300

0.15 –0.25

0.006 –0.010

0.17

.007

0.25 –1.00

0.010 –0.039

Terminal Series No.

Bend up Bend down

Twist Roll

Seam

Seam shall not be open

and no wire allowed out of

the crimping area

Degree

105300

After crimping, the conductor profiles should measure the following.

Terminal

Series No

Wire Size

Conductor Crimp

Insulation Crimp▲

Pull Force

Minimum

Profile

Height

Width (Ref.)

Height (Ref)

Width (Ref)

AWG

mm2

In.

Lb.

105300

0.70 –0.75

0.027 –0.030

1.15

0.045

1.60

0.063

1.55

0.061

22.3

1.70

0.067

1.70

0.067

0.65 –0.70

0.025 –0.027

1.15

0.045

1.55

0.061

1.55

0.061

13.4

1.65

0.065

1.70

0.067

▲To Achieve IPC-A-620 Class 2 Crimps, the following over-all wire insulation diameter ranges are recommended:

Profile A: (UL1061) 1.10mm –1.20mm (0.043in –0.047in)

Profile B: (UL1007) 1.30mm –1.40mm (0.051in –0.055in)

Profile C: (UL1061) 1.05mm –1.15mm (0.041in –0.045in)

Profile D: (UL1007) 1.20mm –1.30mm (0.047in –0.051in)

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. 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.

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.

Hand Crimp Tool for Nano-Fit™Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 10-22-14

WIRE

INSULATION

PUNCH

TERMINAL

WIRE STOP BLADE

Figure 3

TERMINAL

SEATED IN

LOCATOR

SWING

LOCATOR OPEN

Figure 1

HAND

TOOL

OPEN

WIRE

STOP

BLADE

PIVOT

LOCATOR

Figure 4

REMOVE

CRIMPED

WIRE

Figure 2

WIRE

TERMINAL

LOCATOR

INSULATION

PUNCH

INSULATION

ANVIL

WIRE STOP

BLADE

CONDUCTOR ANVIL

CONDUCTOR

PUNCH

1. With the hand tool in the open position, pivot the terminal locator open by pulling on the locator knob and

lift the wire stop blade up. See Figure 1.

2. Insert the terminal into the correct profile until the

terminal is fully seated and stops. Make sure the wire

stop blade is fully in up position.

3. Gently pivot the locator closed.

4. Bring down the wire stop blade. Make sure the wire stop

blade is fully seated on the terminal behind the

conductor grip section.

5. Slide the pre-stripped wire into the terminal; make sure

to aim the wire brush towards the tip point on the wire

stop blade. See Figure 2. Align the wire so that it is

parallel and sitting into the terminal. Maintain a light and

constant pressure on the wire that is seated in the

terminal at all times. (Do not let go of the wire.) Be sure

to hold the wire and terminal in place until the terminal is fully crimped. See Figure 3.

6. Close the tool until the ratchet releases, the tool handles will

then spring open.

7. Lift the wire stop blade up.

8. Carefully remove the crimped terminal. Pivot the terminal

locator slightly out if necessary. See Figure 4.

Note: The tamper proof ratchet action will not release the tool

until it has been fully closed.

Note: To maintain good brush control and a consistent bell

mouth the crimping instructions must be followed.

Hand Crimp Tool for Nano-Fit™Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 10-22-14

INCORRECT

Figure 6

CORRECT

INCORRECT

Terminal Locator Replacement/Change Over

This section describes the procedure for changing locators.

Removal

1. With the tool in the open position, pivot the terminal locator outward.

2. Remove the M4 BHCS. See Figure 4.

Installation

1. Place the replacement locator on the hand tool. Install the M4 BHCS.

See Figure 6.

2. Tighten the screw enough to hold the locator. Make sure the locator can still float freely with hand pressure.

3. Insert the proper terminal fully into the correct profile slot

until the terminal is fully seated and stops. Then gently

pivot the locator closed.

4. With hand pressure, slowly slide the locator to the correct

position. See Figure 6.

5. Gently pivot the locator open without disturbing the

location.

6. Hold the locator firmly in place and slowly tighten the M4

BHCS.

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 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

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 10.

M4 BHCS

PIVOT

LOCATOR

Figure 5

Hand Crimp Tool for Nano-Fit™Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 10-22-14

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 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 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 Nano-Fit™Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 10-22-14

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 Head

Order No.

Tool

Order no.

Tool

Description

Adapter

Order No.

Adapter

Description

Figure

No.

63827-6070

63816-0000

Hand Crimp Frame (Short)

N/A

63816-0050

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0600

Battery Power Crimp Adapter

63816-0250

Battery Power Tool (220 V)

63816-0600

Battery Power Crimp Adapter

63816-0100

Air Power Tool

63816-0700

Air Power Crimp Adapter

Applications for the Modular Crimp Head

Hand Crimp Tool

Battery Powered Tool

Air Powered Tool

Figure 7

Figure 8

Figure 9

MODULAR

CRIMP

HEAD

LOCKING

PINS

HAND CRIMP

FRAME LONG

OR SHORT

Hand Crimp Tool for Nano-Fit™Crimp Terminals

Doc No: ATS-6382760HM Release Date: 10-17-14 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 10-22-14

RATCHET

RELEASE LEVER

HANDLE

SPRING

CRIMPING

SPRING (2)

LOCATOR

Figure 10

M4 X 12mm

LONG BHCS

M4 LOCKNUT

PARTS LIST

Item

Order Number

Description

Quantity

63827-6070

Modular Crimp Head

63816-0000

Hand Crimp Frame (Short)

63827-6075

Locator

63816-0001

Locking Pin

63600-0525

Handle Spring

63600-0520

Crimping Spring

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

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