molex 63827-1170 User manual

Hand Crimp Tool for Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 11-18-13
INSULATION CRIMP
BRUSH
STRIP LENGTH
BELL MOUTH
WIRE
CONDUCTOR
CRIMP HEIGHT
CUT
-
OFF
TAB
SEAM
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63827-1170
Hand Crimp Tool
Ord r No. 63827-1100
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.
 any different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WH A-A-620 Class 2 as indicated, and RoHS compliant.
SCOPE
Products: Ring Tongue Terminal for 14-24 AWG Wire (1.50 - 0.50mm²), etal Strip.
T rminal
S ri s No.
T rminal Ord r No. Wir Siz
Insulation Diam t r
Strip L ngth
IPC/WHMA-A620 (1)
T rminal Insulation
Maximum (2)
R l form only (3)
AWG
mm²
mm
In.
mm
In.
mm
In.
94511
94511
-
1310
94511
-
1311
18-20 1.50 - 0.50 1.75 -2.50 .069 -.098 3.00 .118 5.00-6.00 .197-.236
94511
-
1410
94511
-
1411
94511
-
1520
94511
-
1521
94511
-
1610
94511
-
1611
(1)
To achieve optimum IPC
-
A620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
(3) The terminals above are reeled parts only. Customer to cut off terminal from reel.
DEFINITION OF TERMS
TYPE 4C

Hand Crimp Tool for Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 11-18-13
ANVILS
POWER
CRIMP
HEAD
Figur
1
PUN
CHES
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
Figur
2
CONDITIONS:
After crimping, the conductor profiles should measure the following (See notes below).
T rminal
S ri s No.
Wir Siz
Conductor
Insulation
Pull Forc
Minimum Profil
Crimp H ight
Crimp Width
Maximum
Insulation
H ight
Insulation Width
Maximum
AWG
mm2
mm
in.
mm
in.
mm
in.
mm
in.
N
Lb.
A
B
C
D
94511
---
1.50
2.10
-
2.20
.083
-
.087
3.15 .124
2.95
-
3.10
.116
-
.122
4.20 .165
196
44.0
X
---
1.
00
2.00
-
2.10
.079
-
.083
2.85
-
3.00
.112
-
.118
157
35.3
X
18
0.80
1.90
-
2.00
.075
-
.079
2.75
-
2.90
.108
-
.114
118
26.5
X
20
0.50
1.80
-
1.90
.071
-
.075
2.65
-
2.80
.104
-
.110
78
17.5
X
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.
CAUTION: Install only olex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punch s Installation
1. Insert the Anvils into the bottom slots of the nest. Install the 4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the 4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and R moval
Follow the steps below to install or replace the locator. See Figure 2.
To install th locator
1. Position the locator with the hole over the brass pivot shaft and snap it into place.

Hand Crimp Tool for Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 11-18-13
Figur 6
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
To r mov th 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.
Crimping T rminals
1. Select the desired 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. Some terminals with large insulation
grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be
loaded into the locator in the closed crimp position. See Figure 5.
4. Press down on the wire stop on the locator as shown in Figure 4.
5. Insert the proper terminal into the proper nest opening. ake sure when choosing the nest opening, it will
correspond with the A, B, or C profile on the hand tool.
6. Return the locator to its original position.
7. Turn the Locator Lock Latch up to lock. ake sure that the
terminal is visually centered over the punch.
8. Insert the proper wire over the terminal.
9. Gently touch the wire stop with the end of the wire. See
Figure 6 and 7.
10. Compress the terminal by squeezing the tool handles until
the ratchet mechanism cycle has been completed. Release
handles to open the jaws.
11. Remove the crimped terminal from the terminal locator by
pressing down on the wire stop and gently pulling on the
wire. The terminal locator can be in either position.
Figur 3
LATCH LOCKED LATCH UNLOCKED
HANDLE
OPEN
LOCATOR
CLOSED
Figur 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
TERMINAL
IN PLACE
Figur 4
LOCA
TOR LATCH
IN OPEN POSITION

Hand Crimp Tool for Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 11-18-13
Figur 9
RETRACTOR
SLIDE
12. Visually inspect the crimped terminal for proper
crimp location.
Not : The tamper proof ratchet action will not
release the tool until it has been fully closed.
For th Batt ry Pow r 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. The terminal locator
can be in either position.
3. Visually inspect the crimped terminal for proper
crimp location.
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. ake 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. 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 8A or 8B
for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams (Crimp Hand Tools Only)
(S Figur 12)
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 12.
Miscrimps or Jams (Batt ry Pow r d Tools) (See Figure 9)
Should this tool ever become stuck or jammed in a partially closed position, Do Not force the power head
open or closed. The ram can be retracted before the crimping cycle is complete. To do this push the
retractor slide towards the battery. See Figure 9.
Figur 8B
LUB
RICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 8A
Figur 7
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL

Hand Crimp Tool for Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 11-18-13
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: olex crimp specifications are valid only when used with olex terminals and tooling.
CAUTIONS
1. anually 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 olex terminals specified for crimping with this tool.
CAUTION: Repetitive use of this tool should be avoided.
C rtification
olex 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 olex 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 Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 11-18-13
The chart below shows all applications for this Tool Kit.
Tool Kit
Ord r No.
Tool
Ord r no.
Tool
D scription
Pow r
H ad
Ord r No.
Adapt r
D scription
Figur
No.
63827-1170
6381
0
-
1050
Hand Crimp Frame (Short)
N/A
N/A
10
6381
0
-
100
0
Hand Crimp Frame (Lon
g)
N/A
N/A
10
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp Head
11
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp Head
11
Applications for th Tool Kit
Hand Crimp Tool
Batt ry Pow r d Tool
Figur
10
Figur
11
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 anual or Specification Sheet. See
Chart above for the correct anual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. ake 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.
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT

Hand Crimp Tool for Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 11-18-13
HAND TOOL PARTS LIST
It m Numb r
Ord r Numb r
D scription
Quantity
1
63810
-
1000
Hand Crimp Frame (
Long
)
1
2
6382
7
-
11
70
Tool Kit with
L
ocator
1
3
6382
7
-
11
75
Locator (only)
R
EF
RATCHET
RELEASE SCREW
Figur 12
M4 X 8mm
LONG BHCS
2
1
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
3
WITH TOOL KIT
LOCATOR ONLY

Hand Crimp Tool for Ring Tongue Terminal
Doc No: ATS-6382711H Release Date: 11-18-13 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 11-18-13
Figur 13
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
It m
Ord r No
Engin ring No.
D scription
Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63827-1170 63827-1170 Tool Kit with Locator 1
Visit our Web site at http://www.molex.com