molex 63827-1600 User manual

Hand Crimp Tool Super-Sabre Crimp Terminals
Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 1 of 7
Revision: D Revision Date: 09-23-21
Application Tooling Specification
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 63816-0270 (110 V) or the 63816-0280 (220 V) Battery Powered Tool
Many different tool kits can be used with a single Battery Powered Tool
This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant
SCOPE
Products: Super-Sabre Male and Female Crimp Terminals, 10 AWG.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter (1)
Strip Length
Reel
AWG
mm²
mm
In.
mm
In.
171825
171825-0100
171825-8100
10
—
4.60 Ref.
.181 Ref.
7.9-8.3
0.31-0.33
171826
171826-0100
171826-8100
171826-0200
171826-8200
Customer to cut off terminal from reel: 0.50mm (.020”) maximum cut-off tab.
(1)This terminal series does not have an Insulation grip
DEFINITION OF TERMS
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWIST
ROLL
BEND
DOWN
WIRE
171825 Series
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWIST
ROLL
BEND
DOWN
WIRE
171826 Series
Order Number
63827-1600
TYPE 4C

Hand Crimp Tool Super-Sabre Crimp Terminals
Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 2 of 7
Revision: D Revision Date: 09-23-21
CONDITIONS
After crimping, the conductor profiles should measure the following (see notes below):
Terminal Series No.
Wire Size
Conductor Crimp
Pull Force Minimum
Profile
Height
Conductor Width
AWG
mm2
mm
In.
mm
In.
N
Lb.
A
B
171825
10
—
2.33-2.43
.092-.096
3.60-3.80
.142-.150
356
80
X
171826
2.62-2.72
.103-.107
4.30-4.50
.169-.177
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.
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 performed to check hand tool crimp.
Pull force value must exceed the minimum pull force specifications listed.
CAUTION: Install only Molex 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 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 hand crimp 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.
ANVIL
POWER
CRIMP
HEAD
Figure 1
PUNCH
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

Hand Crimp Tool Super-Sabre Crimp Terminals
Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 3 of 7
Revision: D Revision Date: 09-23-21
Figure 4
WIRE IN
TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
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 Terminals
Swing the terminal locator against the crimp tool and
turn the lock up to lock the locator. Terminals can be
loaded easily while the locator is against the crimp tool
and locked. The spring-loaded locator needs to be in
the up position for terminals to load easily. See Figure
3.
1. To raise the wire stop, press the tab on the wire
stop as shown in Figure 3. Insert the proper
terminal into the nest opening and release the
wire stop to lower it. When choosing the nest
opening, make sure it will correspond with the A
or B profile on the hand tool.
2. Insert the proper pre-striped wire over the terminal. Gently touch the wire stop with the end
of the wire. See Figures 4 and 5.
3. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has
been completed. Release handles to open the jaws.
Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.
4. Remove the crimped terminal from the terminal locator by pressing the tab on the wire stop
and gently pulling on the wire.
5. Visually inspect the crimped terminal for proper crimp location and crimp height.
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. The terminal locator can be in either position.
3. Visually inspect the crimped terminal for proper crimp location.
HANDLE OPEN
LOCK IN UP RIGHT
POSITION
LOCATOR
CLOSED
Figure 3
MALE OR
FEMALE
TERMINAL
PUSH HERE
TO OPEN
WIRE STOP
LOCATOR
ANVIL
TERMINAL
WIRE
PUNCH
WIRE AGAINST STOP
Figure 5
WIRE STOP

Hand Crimp Tool Super-Sabre Crimp Terminals
Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 4 of 7
Revision: D Revision Date: 09-23-21
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 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 a
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 Figures 6A or 6B for
lubrication points.
4. Store the tool in a clean and dry area when it is not in use.
Miscrimps or Jams for Hand Crimp Tools Only (See Figure 9)
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 9.
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, Molex will repair or
exchange the tool kit free of charge. This repair or exchange will not be applicable to altered,
misused or damaged tools.
Handheld crimping tools are intended for low volume, prototyping or repair requirements only.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and
tooling.
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.
CAUTION: Repetitive use of this tool should be avoided.
Figure 6B
LUBRICATION POINTS
(BOTH SIDES) LIGHT
OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 6A

Hand Crimp Tool Super-Sabre Crimp Terminals
Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 5 of 7
Revision: D Revision Date: 09-23-21
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 website 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.
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.
63827-1670
63810-1050
Hand Crimp Frame (Short)
—
—
7
63810-1000
Hand Crimp Frame (Long)
—
—
7
63816-0270
Battery Power Tool (110 V)
63816-0300
Power Crimp Head
8
63816-0280
Battery Power Tool (220 V)
63816-0300
Power Crimp Head
8
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure 7
Figure 8
WARNING: NEVER operate, service or 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 connected to 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.
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT

Hand Crimp Tool Super-Sabre Crimp Terminals
Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 6 of 7
Revision: D Revision Date: 09-23-21
RATCHET
RELEASE SCREW
Figure 9
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810-1000
Hand Crimp Frame (Long)
1
2
63827-1670
Tool Kit with Locator
1
3
63827-1673
Locator Base
1
4
63827-1675
Locator
REF

Hand Crimp Tool Super-Sabre Crimp Terminals
Doc No: ATS-6382716HM Release Date: 01-17-14 UNCONTROLLED COPY Page 7 of 7
Revision: D Revision Date: 09-23-21
Figure 10
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order Number
Engineering No.
Description
Quantity
1
63816-0300
63816-0300
Power Crimp Head
1
2
63827-1670
63827-1670
Tool Kit
1
Application Tooling Support
Phone: (402) 458-TOOL (8665)
E-Mail: [email protected]
Website: www.molex.com/applicationtooling
Molex is a registered trademark of Molex, LLC in the United States of America and may be registered in other countries; all other
trademarks listed herein belong to their respective owners.