molex 63827-3200 User manual

Hand Crimp Tool for Solder Right In-Board Terminals
Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 1 of 6
Revision: A Revision Date: 0 -05-14
INSULATION CRIMP
BRUSH
STRIP LENGTH
BELL MOUTH
CONDUCTO
R
CRIMP HEIGHT
SEAM
CUT
-
OFF TAB
WIRE
Application Tooling
Sp cification Sh t
Modular Crimp H ad
Ord r No. 63827-3270
Hand Crimp Tool
Ord r No. 63827-3200
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
% Modular Crimp Head is removable and can be use in the Air Powered Tool Order No.63 16-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63 16-0700).
% Can also be used in the Battery Powered Tool Order No.63 16-0200 (110 V) or 63 16-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63 16-0600).
SCOPE
Products: Solder Right In-Board Terminals, 22-24AWG.
T rminal
S ri s No.
T rminal Ord r No.
Wir Siz
♦
Insulation Diam t r
UL1007 Wir is R comm nd d Strip L ngth
IPC/WHMA
-
A620 (1)
T rminal
AWG
mm
In.
mm
In.
mm
In.
172677
172677
-
0100
22
-
24
1.30
–
1.65
0.051
–
0.065
1.40
–
1.60
0.055
–
0.062
5.1
–
5.4
0.20
–
0.21
(1)
To achieve optimum IPC
-
A620 Class
2 insulation crimps, use this insulation OD.
DEFINITION OF TERMS
TYPE 4A

Hand Crimp Tool for Solder Right In-Board Terminals
Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 0 -05-14
Crimp Sp cification
After crimping, the conductor profiles should measure the following (See Figure 1).
T rminal S ri s No.
Wir Siz
Conductor
Pull Forc Minimum Profil
Crimp H ight
Crimp
W
idth
AWG
mm
In
.
mm
In.
N
Lb.
A
B
172677
22
0.74
–
0. 0
0.029
–
0.031
1.45
0.057
35.6
X
24
0.6
–
0.74
0.027
–
0.029
1.45
0.057
22.3
5
X
S am
:
shall not be open
and no wire allowed out
of the crimping area
.
Not s:
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 AWG conductors with UL1007 insulation. It may not give a good insulation crimp
support for other insulation styles.
4. Molex does not repair hand tools (see Warranty on page 3). 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. Refer to Molex Quality Crimping
Handbook 63 00-0029 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.
Pr paring T rminals for Crimping
The terminals must be cut from the reel as shown. See Figure 2. The carrier strip hole is used to assist in loading
the terminal in position over the crimp anvils. The carrier strip will help maintain terminal position during crimping
and can be broken off after the crimp is complete.
Crimping T rminals
1. Load the terminal with carrier strip into the proper crimp profile.
Make sure the carrier strip pilot hole fits over the positioning pin.
2. Push the wire stop downward (into the tool frame).
3. Place the properly stripped wire into the open terminal barrel.
Push the wire into the tool until the end of the wire contacts the
wire stop, making sure that all wire strands are inside of the
conductor barrel. See Figures 3 and 4.
4. While holding the wire with one hand, slowly squeeze the tool
handles together to close the tool jaws until the ratchet
mechanism releases. At this point the handles can be released
and will spring open.
5. Remove the crimped terminal and inspect for acceptable crimp
attributes.
Not : The tamper proof ratchet action will not release the tool until it
has been fully closed.
Figur 2
POSITIONING
PIN
LOCATOR
Figur 3
TERMINAL
CARRIER STRIP
WIRE STOP
PUCH DOWN

Hand Crimp Tool for Solder Right In-Board Terminals
Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 0 -05-14
Figur 5
WIRE IN CONDUCTOR CRIMP
WIRE STOP
OPEN
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. 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.
Pull T st Proc dur
Pull testing is to be done with no influence from the
insulation crimp.
Pull testing can be done by the following steps:
1. 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.
2. Load the terminal with the carrier strip into the proper profile make sure the carrier strip pilot hole fits over the
positioning pin on the locator.
3. Do Not close the wire stop.
4. Position a wire form the back side of the hand tool and into the conductor crimp area only. See Figure 5.
5. Carefully crimp the terminal.
6. When pull testing, grip the carrier strip in one jaw and the wire insulation in the other jaw. See Figure 6.
TERMINAL
RM
WIRE
INSULATION
PUNCH
CONDUCTOR
ANVIL
INSULATION
ANVIL
Figur 4
CONDUCTOR
PUNCH
LOCATOR
WIRE STOP
PULL TESTER
TERMINAL
CLAMP
WIRE
Figur 6
PULL TESTER
WIRE CLAMP
CLAMP TH
E
CARRIER STRIP
INTO THE TESTER

Hand Crimp Tool for Solder Right In-Board Terminals
Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 0 -05-14
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 6.
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 th Modular Crimp H ad
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 Solder Right In-Board Terminals
Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 0 -05-14
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 H ad
Ord r No.
Tool
Ord r no.
Tool
D scription
Adapt r
Ord r No.
Adapt r
D scription
Figur
No.
63 27-3270
63 16
-
0000
Hand Crimp Frame (Short)
N/A
N/A
3
63 16
-
0050
Hand Crimp Frame (L
ong)
N/A
N/A
3
63 16
-
0200
Battery Power
Tool (110 V)
63 16
-
0600
Battery Power Crimp Adapter
4
63 16
-
0250
Battery Power
Tool (220 V)
63 16
-
0600
Battery Power Crimp Adapter
4
63 16
-
0100
Air
Po
w
er
Tool
63 16
-
0700
Air Power Crimp Adapter
5
Applications
for th Modular Crimp H ad
Hand Crimp Tool
Batt ry Pow r d Tool
Air Pow r d Tool
Figur
3
Figur
4
Figur
5
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for Solder Right In-Board Terminals
Doc No: ATS-63 2732HM Release Date: 0 -05-14 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 0 -05-14
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figur 6
2
5
1
M4 X
20
mm
LONG BHCS
(2)
PARTS LIST
It m
Ord r Numb r
D scription
Quantity
1
63 27
-
3
2
70
Modular
Crimp
Head
1 (
R
ef)
2
63 16
-
00
0
0
Ha
nd Crimp
Frame
(
Short
)
1
(
R
ef)
3
63 27
-
3
2
75
Locator
Plate
1
4
63 16
-
0001
Locking
Pin
2
5
63600
-
0525
Handle Spring
1
6
63600
-
0520
Crimping Spring
2
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