Molex 63827-8600 Manuale utente

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 1 of 8

Revision: B Revision Date: 08-20-19

INSULATION

CRIMP

BRUSH

STRIP LENGTH

BELL MOUTH

CONDUCTOR

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLL

WIRE

TWIST

CUT-OFF

TAB

SEAM

Application Tooling Specification

FEATURES

A full cycle ratcheting hand tool ensures complete crimps

Ergonomic soft grip handles for comfortable crimping

A precision user-friendly terminal locator wire stop holds terminals in the proper crimping

position

Right- and left-handed applications

Dies and Locator from this tool can be used in the Battery Powered Tool Order No. 63816-0270

(110 V) or 63816-0280 (220 V), with the use of the 63816-0800 Crimp Head

Many different tool kits can be used with a single Battery Powered Crimp Tool

This tool is IPC/WHMA-A-620 Class 2 compliant (see page 2)

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

SCOPE

Products: Ditto Wing Genderless Interconnects Terminal, 24–26 AWG.

Terminal

Series No.

Terminal Order No.

Wire Size

Insulation Diameter

Strip Length

▲IPC/WHMA-A-620 (1)

Terminal (2)

Reel

AWG

In.

150197

150197-0002

24-26

0.80-1.55

.031-.061

1.05-1.50

.041-.059

2.30-2.80

.090-.110

150200

150200-0002

150200-0012

24-26

0.80-1.55

.031-.061

1.05-1.50

.041-.059

2.30-2.80

.090-.110

(1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range.

(2) Overall insulation OD specification for terminal.

DEFINITION OF TERMS

Order Number

63827-8600

Type 4D

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 2 of 8

Revision: B Revision Date: 08-20-19

▲Insulation Crimp Note

Due to the terminal’s insulation grip design

and insulation diameter range, this tool uses

overlap form geometry in the insulation

punch. This produces an overlap insulation

crimp (A-620 compliant). Although the

insulation punch profile may appear lopsided,

this is a normal condition for this tool. See

figure to the right. Some tools with multiple

crimp pockets may not have the overlap

profile on all pockets.

CONDITIONS

After crimping, the conductor profiles should measure the following:

Terminal Series No

Wire Size

Conductor Crimp

Height

Width

AWG

In.

150197

150200

0.95–1.05

.037-.041

1.40-1.50

.055-.059

0.95–1.00

.037-.039

Terminal

Series No

Wire Size

Insulation Crimp Maximum

Pull Force

Minimum

Profile

Height (Ref.)

Width (Ref.)

AWG

In.

Lb.

150197

150200

1.75-1.85

.069-.073

1.75-1.85

.069-.073

26.7

6.0

1.55-1.65

.061-.065

1.55-1.65

.061-.065

1.75-1.85

.069-.073

1.75-1.85

.069-.073

17.8

4.0

1.50-1.60

.059-.063

1.40-1.50

.055-.059

▲To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:

Profile A: 1.30-1.40mm (.051-.055”) Profile C: 1.10-1.20mm (.043-.047”)

Profile B: 1.35-1.55mm (.053-.061”) Profile D: 0.80-1.00mm (.031-.039”)

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.

Note

A crimp height chart is provided with this document as Reference Only. Due to 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.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 3 of 8

Revision: B Revision Date: 08-20-19

Figure 5

TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

PRE-STRIPPED

WIRE

TERMINAL

RELEASE

LOCATOR BUTTON

TERMINAL

Figure 3

LOCATOR

PUSHED

THROUGH

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

OPERATION

CAUTION: Crimp only the Molex terminals listed in the scope for this tool. Do not crimp

hardened objects as 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 Terminals

1. Select the desired terminal listed from the preceding charts and

install it in the proper locator (See chart above and see Locator

Replacement on page 4).

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 in the locator button, 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.

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 through the terminal and

against the wire stop. See Figure 5.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figure 4

FIRST RATCHET

POSITION

OPEN

POSITION

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figure 1

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figure 2

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 4 of 8

Revision: B Revision Date: 08-20-19

7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been

completed. Release the handles to open the jaws.

Note: 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 proper

crimp location.

10. On some large O.D. wires, it may not be possible to

insert the wire with the tool partially closed. Those

wires should be inserted with the hand tool in the

open position. Insert the wire above the terminal in

the punch and against the wire stop, and then close

the tool. See Figure 6.

Locator Replacement

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 hand crimp tool.

2. Squeeze gently on the lower area

shown in Figure 7A 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 7A.

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 7B.

6. Holding onto the lower part of the

locator with your thumb and index

finger, insert the locator top hooks (2)

into the hand tool 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.

TERMINAL

Figure 6

WIRE

STOP

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE DOWN

POSITION

Figure 7B

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 5 of 8

Revision: B Revision Date: 08-20-19

Right- or Left-Handed Operation

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 BHCS, which is holding the

upper tooling.

3. Flip the upper tooling to the opposite side,

and replace the M3 BHCS. 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

8 and 9.

4. Do the same thing with the lower tooling,

and tighten the M3 screws. Be sure the

small markings line up.

5. Reinstall the locator by following the

instructions in the locator replacement

section.

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 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. See Figure

10. 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 the crimping

area. Oil transferred from the crimping area onto certain

terminations may affect the electrical characteristics of an

application.

5. When the 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.

MATCH

UP MARKS

FRONT

BACK

Figure 9

LUBRICATION POINTS

(BOTH SIDES) LIGHT

OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figure 10

Figure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 6 of 8

Revision: B Revision Date: 08-20-19

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 11.

How to Adjust Tool Preload (See Figure 12)

This hand tool is factory preset to 25-45 pounds handle 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 12. 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.

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.

RATCHET RELEASE

LEVER

Figure 11

Figure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 7 of 8

Revision: B Revision Date: 08-20-19

CERTIFICATION

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 (.500”) 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 Ditto Wing Genderless Interconnects Terminals

Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 8 of 8

Revision: B Revision Date: 08-20-19

Figure 13

PARTS LIST

Item Number

Order Number

Description

Quantity

REF

63827-8600

Hand Crimp Tool

Figure 13

63827-8675

Locator Assembly (Red)

63810-0104

Spring, Return

63810-0105

Spring, Ratchet

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.

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