molex 63827-5470 User manual

Hand Crimp Tool for ULTRA-FIT Crimp Terminals
Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 1 of 6
Revision: A Revision Date: 01-30-15
TYPE 4A
ROLLING
INSULATION
CRIMP HEIGHT
BRUSH
STRIP LENGTH
BELL MOUTH
CONDUCTOR
CRIMP HEIGHT
BEND DOWN
BEND UP
TWISTING
SEAM
CUT-OFF
TAB
WIRE
Application Tooling
Specification Sheet
Modular Crimp Head
Order No. 63827-5470
Hand Crimp Tool
Order No. 63827-5400
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.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: ULTRA-FIT Crimp Terminals, 20-22 AWG (UL1061) wires.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
UL1061 Wire is Recommended
Strip Length
AWG
mm²
Type
mm
In.
mm
In.
172253
172253-3111
172253-3112
20-22
---
UL1061
1.22-1.44
.048-.057
3.50-4.00
.138-.158
172253-3123
DEFINITION OF TERMS

Hand Crimp Tool for ULTRA-FIT Crimp Terminals
Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 01-30-15
CRIMP SPECIFICATION
Terminal Series No.
Bell mouth
Cut-off Tab Max (Ref)
Conductor Brush
mm
In.
mm
In.
mm
In.
172253
0.30-0.50
.012-.020
0.20
.008
0.00-1.00
.000-.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 (Max)
Degree (Max)
172253
3
3
3
5
After crimping, the conductor profile should measure the following.
Terminal Series No.
Wire Size
Conductor
Profile
Crimp Height
Crimp Width (Max.)
AWG
mm2
mm
In.
mm
In.
20
22
172253
20
---
0.82-0.92
.032-.036
1.60-1.70
.063-.067
X
22
---
0.73-0.83
.029-.033
1.60-1.70
.063-.067
X
Terminal Series No.
Wire Size
Insulation
Pull Force Minimum
Crimp Height (Max.)
Crimp Width (Max.)
AWG
mm2
mm
In.
mm
In.
N
Lb.
172253
20
---
1.90
.075
1.95
.077
57.9
13.0
22
---
1.70
.067
1.65
.065
35.6
8.0
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; however crimp force is adjustable (See instructions above).
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). 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 ULTRA-FIT Crimp Terminals
Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 01-30-15
WIRE
INSULATION
PUNCH
TERMINAL
WIRE STOP BLADE
Figure 2
Figure 3
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 up 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.
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.
7. Lift the wire stop blade up.
8. Carefully remove the crimped terminal.
Note: To maintain good brush control and a consistent
bell mouth the crimping instructions must be followed.
Terminal Locator Replacement
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 new locator, (See Chart on page 2), on the hand tool. Install the M4 BHCS. See Figure 4.
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 5.
TERMINAL
SEATED IN
LOCATOR
SWING
LOCATOR
OPEN
Figure 1
HAND TOOL
OPEN
WIRE
STOP
BLADE

Hand Crimp Tool for ULTRA-FIT Crimp Terminals
Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 01-30-15
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 9.
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.
M4 BHCS
PIVOT LOCATOR
Figure 4
INCORRECT
Figure 5
CORRECT
INCORRECT

Hand Crimp Tool for ULTRA-FIT Crimp Terminals
Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 01-30-15
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
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.
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.
63827-5470
63816-0000
Hand Crimp Frame (Short)
N/A
N/A
6
63816-0050
Hand Crimp Frame (Long)
N/A
N/A
6
63816-0200
Battery Power Tool (110 V)
63816-0600
Battery Power Crimp Adapter
7
63816-0250
Battery Power Tool (220 V)
63816-0600
Battery Power Crimp Adapter
7
63816-0100
Air Power Tool
63816-0700
Air Power Crimp Adapter
8
Applications for the Modular Crimp Head
Hand Crimp Tool
Battery Powered Tool
Air Powered Tool
Figure 6
Figure 7
Figure 8
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for ULTRA-FIT Crimp Terminals
Doc No: ATS-6382754HM Release Date: 01-30-15 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 01-30-15
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
3
6
4
Figure 9
M4 X 6mm
LONG BHCS
2
5
1
PARTS LIST
Item
Order Number
Description
Quantity
1
63827-5470
Modular Crimp Head
1
2
63816-0000
Hand Crimp Frame (Short)
1
3
63827-5475
Locator
1
4
63816-0001
Locking Pin
2
5
63600-0525
Handle Spring
1
6
63600-0520
Crimping Spring
2
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