Hand Crimp Tool for CMC Male Crimp Terminals
Modular Crimp Head
Order No. 63827-5570
FEATURES
Application Tooling
Specification Sheet
TYPE 4A
Hand Crimp Tool
Order No. 63827-5500
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
A-620 Class 2 compliant as indicated on page 2 and RoHS compliant
Modular Crimp Head is removable and can be used 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:
CMC Wire-to-Wire Connector 0.64, Male Terminal, 0.3-0.5mm²
Terminal Order No.
Terminal Series No.
Wire Size
(2) Insulation Diameter
Maximum
Strip Length
(1) Available in Reel
AWG mm²
mm
In.
mm
In.
form only
0.3
1.40
0.055
501827
501827-0101
N/A 0.35
1.40
0.055
3.4-3.8 .13-.15
0.5
1.60
0.063
(1) Customer to cut off terminal from reel: 0.30mm (0.012 in) maximum cut-off tab.
(2) See Conditions on page 2.
BELL MOUTH
INSULATION
CRIMP
SEAM
ROLLING
TWISTING
BEND
DOWN
CUT-OFF TAB
CONDUCTOR
COND.CRIMP
CRIMP
HEIGHT
BEND UP
DEFINITION OF TERMS
BRUSH
STRIP
LENGTH
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
Doc No: ATS-6382755HM
Revision: A
Release Date: 01-12-18
Revision Date: 01-12-18
UNCONTROLLED COPY
Page 1 of 7
Hand Crimp Tool for CMC Male Crimp Terminals
CRIMP SPECIFICATIONS
Terminal Series No.
501827
Bell Mouth
mm
In.
0.20-0.55 .008-.022
Conductor Brush
mm
In.
0.20-1.00 .008-.040
Bend Up Bend Down
Degrees
3
3
Twist Roll
Degrees
4
6
After crimping, the crimped areas should measure the following:
Conductor Crimp
Insulation Crimp
Pull Force
Profile
Terminal Wire Size
Height (Ref.)
Width (Ref.) Height (Ref.) Width (Ref.) Minimum
Series No.
mm
2
mm
In.
mm In. mm In.
mm In.
N Lb. A B
0.3 AVSS 0.77-0.87 .030-.034 1.40 .055 1.70 .067 1.95 .077 58.8 13 X
0.35 FLRY-B 0.77-0.87 .030-.034 1.40 .055 1.70 .067 1.95 .077 55 12 X
501827
0.5 AVSS 0.84-0.94 .033-.037 1.40 .055 1.90 .075 2.00 .079 90 20
X
0.5 FLRY-B 0.84-0.94 .033-.037 1.40 .055 1.90 .075 2.00 .079 70 16
X
To
achieve IPC-A-620 Class 2 crimps, the following wire insulation diameter ranges are recommended:
Profile A:
1.30-1.40mm (.052-.055 inch)
Profile B:
1.50-1.60mm (.059-.063 inch)
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.
HAND TOOL
OPEN
SWING
LOCATOR
OPEN
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.
WIRE
STOP BLADE
1. With the hand tool in the open position, pivot
Figure 1
the terminal locator open by pulling on the
locator knob, and lift up on the wire stop
blade. 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 toward 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 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.
TERMINAL
SEATED IN
LOCATOR
Doc No: ATS-6382755HM
Revision: A
Release Date: 01-12-18
Revision Date: 01-12-18
UNCONTROLLED COPY
Page 2 of 7
Hand Crimp Tool for CMC Male Crimp Terminals
WIRE STOP
BLADE
LOCATOR
WIRE
CONDUCTOR
PUNCH
WIRE STOP
BLADE
TERMINAL
INSULATION
PUNCH
INSULATION
ANVIL
WIRE
Figure 3
Figure 2
TERMINAL
CONDUCTOR
ANVIL
INSULATION
ANVIL
Note:
The tamper-proof ratchet action will not release the tool until it has been fully closed.
Note:
To maintain good brush control and a consistent bell mouth, the crimping instructions must be followed.
Terminal Locator Replacement/Changeover
This section describes the procedure for changing locators.
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 proper locator (See Chart on page 2) on the hand
M4 BHCS
tool. Install the M4 BHCS. See Figure 4.
PIVOT LOCATOR
2. Tighten the screw enough to hold the locator. Make sure the
Figure 4
locator can still float freely with hand pressure.
3. Insert the proper terminal 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.
5. Gently pivot the locator open without disturbing the
location.
6. Hold the locator firmly in place, and slowly tighten
the M4 BHCS.
CORRECT
INCORRECT
Figure 5
INCORRECT
Doc No: ATS-6382755HM
Revision: A
Release Date: 01-12-18
Revision Date: 01-12-18
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool for CMC Male Crimp Terminals
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. 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 the 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.
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, 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:
Repetitive use of this tool should be avoided.
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.
Doc No: ATS-6382755HM
Revision: A
Release Date: 01-12-18
Revision Date: 01-12-18
UNCONTROLLED COPY
Page 4 of 7
Hand Crimp Tool for CMC Male Crimp Terminals
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 above). The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling are damaged or worn, a new tool must be purchased.
5. Pull force should be used as the final criterion 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.
CAUTION:
Molex crimp specifications are valid only when used with Molex terminals and tooling.
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.
Doc No: ATS-6382755HM
Revision: A
Release Date: 01-12-18
Revision Date: 01-12-18
UNCONTROLLED COPY
Page 5 of 7
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