molex 63827-2100 User manual

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 12-13-13
INSULATION
CRIMP ▲
BRUSH
STRIP LENGTH
CONDUCTOR
CRIMP HEIGHT
FRONT
CUT-OFF TAB
SEAM
BELL MOUTH
WIRE
REAR CUT-OFF TAB
Application Toolin
Specification Sheet
Tool Kit
Order No. 63827-2170
Hand Crimp Tool
Order No. 63827-2100
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 and Crimp Tool or the 63816-0300 Power Crimp ead which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/W MA-A-620 Class 2 and Ro S compliant.
SCOPE
Products: .250 Slip-in Receptacle Terminals for 14-18 AWG Wire.
Terminal Series No.
Terminal
Order No.
Wire Size
Insulation Diameter
Strip Len th

Reel Form Only
AWG
mm²
mm
In.
mm
In.
35725
35725-2400
35725-2410
35725-2411
14
2.00
3.2-3.8 .126-..150 6.00-6.80 .236-.268
16
1.30
18
0.80

Customer to
c
ut
off
terminal from reel
:
Front
and Rear
Cut
-
off Tab
0
.
5
0mm (.0
2
0
”)
maximum
.
DEFINITION OF TERMS
TYPE 4C

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 12-13-13
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 – compliant). While
the insulation punch profile may appear
“lopsided”, this is a normal condition for this
tool. See figure to the right. (Some tools with
multiple crimp pockets may not have the
“overlap” profile on all pockets).
CONDITIONS:
After crimping, the conductor profiles should
measure the following (see notes below).
Terminal Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum Profile
Hei ht
Width (Ref)
Hei ht
(Ref)
Width (Ref)
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lbs
A
B
C
35725
14
2.00
1.
90
-
2.00
.0
7
5
-
.0
7
9
2.
9
5
.1
16
4.40
.1
73
4.
25
.1
6
7
2
45
55.
1
X
16
1.30
1.
75
-
1.
8
5
.0
69
-
.0
73
2.
9
5
.1
16
4.35
.1
71
4.0
0
.1
5
7
1
7
6
39.6
X
18
0.80
1.
6
0
-
1.
7
0
.0
63
-
.0
67
2.
9
5
.
116
4.
40
.1
7
3
4.
2
0
.1
6
5
1
27
28.6
X



To Achieve IPC
-
A
-
620 Class 2 Crimps, the followin over
-
all wire insulation diameter ran es are rec
ommended:
1. Profile A (18 AWG): 3.20-3.30mm (.126-.130 inch)
2. Profile B (14 AWG): 3.20-3.50mm (.126-.138 inch)
3. Profile C (16 AWG): 3.20mm (.126 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.
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 preformed 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 ead 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 B CS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long B CS and tighten in place. See
Figure 1.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
P
UNCH
WIRE

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 12-13-13
SWING OPEN
TERMINAL
PUSH HER
E TO
OPEN WIRE STOP
LOCATOR
TERMINAL
IN PLACE
Fi ure 4
LOCATOR LATCH
IN OPEN POSITION
ANVILS
POWER
CRIMP
HEAD
Fi ure 1
PUNCHES
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
Fi ure
2
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 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.
Crimpin Terminals
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 Figure1. Insert the proper terminal into the proper
nest opening. Make sure when choosing the nest opening, it will correspond with the A, B or C profile on the
hand tool.
Fi ure 3
LATCH LOCKED
LATCH UNLOCKED

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 12-13-13
Fi ure 6
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Fi ure 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
5. Return the locator to its original position.
6. Turn the Locator Lock Latch up to lock. Make sure that
the terminal is visually centered over the punch.
7. Insert the proper wire over the terminal.
8. Gently touch the wire stop with the end of the wire.
See Figure 6 and 7.
9. Compress the terminal by squeezing the tool handles
until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
10. 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.
11. Visually inspect the crimped terminal for proper crimp
location.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
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.
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.
Fi ure 7
WIRE
INSULATION
PUNCH
CONDUCTOR
ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 12-13-13
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
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 for Crimp Hand Tools
Only (See Fi ure 11)
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 11.
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: Molex crimp specifications are valid only when used with Molex terminals and tooling.
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: Repetitive use of this tool should be avoided.
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 web site for the Quality Crimp andbook 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.
Fi ure 8B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Fi ure 8A

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 12-13-13
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 Fi ure No.
63827-2170
6381
0
-
1050
and Crimp Frame (Short)
N/A
N/A
9
6381
0
-
100
0
and Cri
mp Frame (Long)
N/A
N/A
9
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0300
Power Crimp ead
10
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp ead
10
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Fi ure
9
Fi ure
10
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp ead 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 into 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.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 12-13-13
RATCHET
RELEASE SCREW
Fi ure 11
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
and Crimp Frame (Long)
1
2
6382
7
-
21
70
Tool
Kit with
Locator
1
3
63811
-
47
7
3
Locator Base
1
4
6382
7
-
21
75
Locator (only)
R
EF

Tool Kit for 250 Slip-in Receptacle Terminals
Doc No: ATS-6382721 M Release Date: 12-13-13 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 12-13-13
Fi ure 12
1
2
2
M
4
by
8
Lon
BHCS
M
4
by
18
Lon
BHCS
M
4
by
10
Lon
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
En ineerin No.
Description
Quantity
1
63816-0300 63816-0300 Power Crimp ead 1
2
63827-2170 63825-6570 Tool Kit with Locator 1
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