Molex 63827-8770 Manuale utente

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 1 of 9

Revision: A Revision Date: 06-05-15

INSULATION

CRIMP ▲

STRIP LENGTH

CONDUCTOR

CRIMP HEIGHT

CUT-OFF

TAB

SEAM

BELL MOUTH

WIRE

CONDUCTOR

BRUSH

BEND UP

TWISTING

ROLLING

BEND

DOWN

SEAL

Application Tooling

Specification Sheet

Tool Kit

Order No. 63827-8770

Hand Crimp Tool

Order No. 63827-8700

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

Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.

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

SCOPE

Products: Sealed Single Contact Terminal for S8 and T20 Socket

Terminal

Series No.

Terminal Order No.

Wire Size and Type

Insulation Diameter

Strip Length

Reel Form Only

mm²

Type

In.

49869

49869-9702

0.5

AVS

2.0 –2.1

0.078 –0.083

5.0 –5.5

0.20 –0.22

0.75

FLRY-A

1.7 –1.9

0.067 –0.075

0.85

AVS

2.1 –2.3

0.083 –0.091

Customer to cut off terminal from reel: 0.30mm (.012”) maximum Cut-off Tab.

DEFINITION OF TERMS

TYPE 4C

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 2 of 9

Revision: A Revision Date: 06-05-15

CRIMP SPECIFICATION

Terminal Series No.

Bell mouth

Conductor Brush

Bend up Bend Down

Twist Roll

In.

Degrees Max.

49869

0.30 –0.60

.012 –0.024

0.30 –0.80

.012 –0.031

After crimping, the crimp profiles should measure the following:

Terminal

Series No.

Wire Size

Conductor

Pull Force

Minimum

Profile

Seam

Seam shall not be

open and no wire allowed

out of the crimping area

Crimp Height

Crimp Width

mm2

In.

Lb.

49869

0.50

1.35–1.45

0.053–0.057

2.10–.20

0.083–0.087

88.3

0.75

1.45–1.50

0.057–0.059

117.8

26.5

0.85

1.45–1.55

0.057–0.061

127.5

28.7

Terminal Series No.

Wire Size

Insulation Diameter

Single Wire Seal

Seal Crimp

Crimp Height

Crimp Width

mm2

In.

Order No.

Color

In.

49869

0.50

2.0–2.1

0.078–0.083

49454-9002

Red

3.80–4.00

0.150–0.157

4.20–4.40

0.165–0.173

0.75

1.7–1.9

0.067–0.075

0.85

2.1–2.3

0.083–0.091

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 manual as Reference Only. Due to the wide range of wires, strands,

insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,

destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the

minimum pull force specifications listed.

CAUTION: Crimp only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool frame or crimping dies.

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 3 of 9

Revision: A Revision Date: 06-05-15

ANVILS

POWER

CRIMP

HEAD

Figure 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure 2

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the steps below:

Anvils and Punches Installation

1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See

Figure 1.

Locator Installation and Removal

Follow the steps below to install or replace the locator. See Figure 2.

To install the locator

1. Position the locator with the hole over the brass pivot shaft and snap it into place.

To remove the locator

1. Open the crimp hand tool.

2. Swing the existing locator open and away from the

hand tool.

3. Firmly press down on the brass pivot shaft with your

thumb, while pulling the locator up. Slip the locator

off the top of the brass pivot shaft.

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.

Figure 3

LATCH LOCKED

LATCH UNLOCKED

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 4 of 9

Revision: A Revision Date: 06-05-15

TERMINAL

PRE-STRIPPED

WIRE WITH SEAL

Figure 5

WIRE STOP

BLADE

Figure 6

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL

LOCATOR

INSULATION ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

SEAL

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

TERMINAL

IN PLACE

Figure 4

LOCATOR LATCH

IN OPEN POSITION

Crimping Terminals

1. Crimp only the terminal listed in the preceding charts.

2. Turn the Locator Lock Latch down to unlock. See Figure 3.

3. Swing the terminal locator away from the crimp tool shown in Figure 4.

4. Press down on the wire stop on the locator as shown in Figure 4. Insert the terminal into the proper nest

opening. Make sure when choosing the nest opening, it will correspond with the correct profile on the hand

tool.

5. Return the locator to closed position.

6. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.

7. Insert the proper wire (with the seal installed) over the terminal.

8. Gently touch the wire stop with the end of the wire and align the seal with the grips on the terminal. See Figure 5

and 6.

Note: The tamper proof ratchet action will not release the tool until it has been fully closed.

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

Release handles to open the jaws.

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 5 of 9

Revision: A Revision Date: 06-05-15

10. Unlock the locator latch and swing the locator open.

11. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire.

12. Visually inspect the crimped terminal for an acceptable crimp.

For the Battery Power Tool:

1. Cycle the Battery Power Tool to crimp the terminal to the wire.

2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on

the wire.

3. Visually inspect the crimped terminal for an acceptable crimp.

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 in the tool head are protected with a

thin coat of high quality machine oil. Do not

oil excessively. This tool was engineered for

durability, but like any fine piece of

equipment, it needs cleaning and lubrication

for a maximum service life of trouble-free

crimping. The use of light oil, such as 30

weight automotive oil, every 5,000 crimps or

monthly, will significantly enhance the tool life

and ensure a stable calibration. See Figure 7A or 7B for lubrication points.

4. Store the tool in a clean and dry area when not in use.

Miscrimps or Jams for Crimp Hand Tools Only (See Figure 10)

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 rotating the small slotted screw marked with an arrow. See Figure 10.

Warranty

This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange

will not be applicable to altered, misused, or damaged tools.

CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.

WIRE

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figure 7A

Figure 7B

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 6 of 9

Revision: A Revision Date: 06-05-15

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: Repetitive use of this tool should be avoided.

Certification

Molex does not certify or re-certify commercial grade 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, which has been stripped

12.7mm (1/2”) long, so 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 web site for the Quality Crimp Handbook for more information on pull

testing.

When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and

replaced.

This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 7 of 9

Revision: A Revision Date: 06-05-15

The chart below shows all applications for this Tool Kit.

Tool Kit

Order No.

Tool

Order no.

Tool

Description

Power Head

Order No.

Adapter

Description

Figure

No.

63827-8770

63810-1050

Hand Crimp Frame (Short)

N/A

63810-1000

Hand Crimp Frame (Long)

N/A

63816-0200

Battery Power Tool (110 V)

63816-0300

Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300

Power Crimp Head

Applications for the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure 8

Figure 9

WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper

instruction and without first reading and understanding the instructions in the proper Manual or

Specification Sheet. See Chart above for the correct Manual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the

power is turned off.

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.

POWER

CRIMP

HEAD

LOCKING PINS

BATTERY

POWERED

TOOL

TOOLING KIT

HAND CRIMP

FRAME LONG

AND SHORT

TOOLING KIT

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 8 of 9

Revision: A Revision Date: 06-05-15

RATCHET

RELEASE SCREW

Figure 11

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810-1000

Hand Crimp Frame (Long)

63827-8770

Tool Kit with Locator

63827-8775

Locator (only)

REF

Hand Crimp Tool for Sealed Single Contact Terminals

Doc No: ATS-6382787HM Release Date: 06-05-15 UNCONTROLLED COPY Page 9 of 9

Revision: A Revision Date: 06-05-15

Figure 12

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

Item

Order No

Engineering No.

Description

Quantity

63816-0300

Power Crimp Head

63827-8770

Tool Kit

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

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