molex 63827-5000 User manual

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal
Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 1 of 7
Revision: Revision Date: 05-24-17
INSULATION
CRIMP
BRUSH
STRIP LENGTH
BELL MOUTH
CONDUCTOR
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
WIRE
TWISTING
CUT
-
OFF
TAB
SEAM
HAND CRIMP
TOOL
Application Tooling
Sp cification Sh t
Ord r No. 63827-5000
FEATURES
 A full cycle ratcheting hand tool ensures complete crimps
 Ergonomic soft grip handles for comfortable crimping
 A precision, user-friendly terminal locator holds terminals in the proper crimping position
 Right and Left handed applications
 Dies and Locator from this tool can be used in the attery-Powered Tool Order No. 63816-0200 (110 V) or
63816-0250 (220 V) with the use of the 63816-0800 Crimp Head
 Many different tool kits can be used with a single attery-Powered Crimp Tool
 This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal, 28 AWG.
T rminal S ri s No.
T rminal Ord r No.
R l Form Only (1)
Wir Siz
Insulation Diam t r
(Max)
Strip L ngth
AWG
mm²
mm
In.
mm
In.
104505
104505
-
8003
28
0.089
0.97
.38
0
1.10
-
1.40
.043
-
.055
(
1
)
Customer to cut off terminal from reel: 0.10mm (.004”) maximum Cut
-
O
ff Tab.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal
Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 2 of 7
Revision: Revision Date: 05-24-17
RELEASE
LOCATOR
BUTTON
TERMINAL
Figur 3
LOCATOR
PUSHED
THROUGH
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
CONDITIONS
After crimping, the conductor profiles should measure the following:
T rminal
S ri s No.
Wir Siz
Conductor Crimp
Insulation Crimp
(R f)
Pull Forc
Minimum Profil
H ight
Width (R f.)
H ight
Width
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
28
104505
2
8
0.089
0.
44
-
0.
48
.0
17
-
.0
19
0.90
.0
35
1.
15
.0
45
0.90
.035
9.8
2.20
X
Tool Qualification Not s
1. Pull force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.
Not :
A crimp height chart is provided with this document
as reference only. ecause of the wide range of
wires, strands, insulation diameters and durometers
available, 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.
OPERATION
CAUTION: Crimp only the Molex terminals
listed in the scope for this tool. Do not crimp
hardened objects because damage can occur to the tool frame or crimp dies.
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. See Figure 1.
Crimping T rminals
1. Select the desired terminal listed in the preceding charts.
2. Make sure the center of the locator is in the down position. With the locator attached, push the locator button
on the back of the hand tool to bring the locator forward through the tooling. See Figure 2.
3. While holding the locator button in, load the terminal into the proper nest opening in the locator based on the
wire gauge or terminal type markings on the hand tooling. See Figure 3.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figur 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figur 1

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal
Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 3 of 7
Revision: Revision Date: 05-24-17
PARTIALLY
CLOSE HANDLE
TOOLING PARTIALLY
CLOSED
Figur 4
FIRST RATCHET
POSITION
OPEN
POSITION
4. Release the locator button, allowing the locator to return to the crimping
position.
5. Close the tool handle until the first ratchet position engages. See Figure 4.
6. Insert the properly stripped wire above the terminal and against the locator.
See Figure 5.
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism
cycle has been completed. Release the handles to open the jaws.
Not : The tamper-proof ratchet action will not release the tool until it has been fully closed.
8. Remove the crimped terminal from the terminal locator by pulling on the wire.
9. Visually inspect the crimped terminal for the proper crimp location.
Locator R plac m nt
See the parts list on the last page of this document for
the proper locator order number. Follow the steps below
to replace the locator:
1. Open the crimp hand tool.
2. Squeeze gently on the lower area shown in Figure
6A with your thumb and index finger. The lower
tabs of the locator should disengage from the hand
tool.
3. Lift and pull away from the hand tool. The top
locator hooks should slip out of the top slots easily.
See Figure 6A.
4. To reinstall the new locator, make sure the hand
tool is in the open position.
5. Press the red insert down as far as it will go as
shown in Figure 6 .
6. Holding onto the lower part of the locator with your
thumb and index finger, insert the locator’s top hooks (2) into the hand tool’s top slots.
7. Rotate the locator down, and press the lower tabs into the two bottom slots of the hand tool. To secure the
locator into place, the lower tabs must snap into place on the hand tool frame.
Figur 5
LOCATOR
TERMINAL WIRE AGAINST THE LOCATOR
TERMINAL
PRE
-
STRIPPED
WIRE
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figur 6A
TOP HOOKS
TOP SLOTS OF
HAND TOOL
LOWER TABS
MAKE SURE
CENTER OF
LOCATOR
IS IN THE
DOWN POSITION
F
igur 6
B

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal
Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 4 of 7
Revision: Revision Date: 05-24-17
Figur 7
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Figur 8
Right or L ft Hand Op ration
This hand tool has an added feature that can be
converted from a right handed application to a left
handed application. It is necessary to reverse the
tooling if using the left handed application along with
the locator. Follow the steps below:
1. The locator must be removed before reversing the
tooling.
2. Remove the M3 HCS, which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side, and
replace the M3 HCS. Make sure the small
markings on the front and back of the hand tool
frame match up and are on the outside of the hand
tool frame. See Figures 7 and 8.
4. Do the same thing with the lower tooling, and tighten
the M3 screws. e sure the small markings line up.
5. Reinstall the locator by following the instructions in the
locator replacement section.
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 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 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figur 9

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal
Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 5 of 7
Revision: Revision Date: 05-24-17
Figur 1
1
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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 pressing up
on the ratchet release lever in the movable handle. See Figure 10.
How to Adjust Tool Pr load (S Figur 11)
This hand tool is factory preset to 25-45 pounds preload. It may be necessary
over the life of the tool to adjust tool handle preload force. Listed below are the
steps required to adjust the crimping force of the hand tool to obtain proper crimp conditions:
1. Hold the hand tool in the palm of your
hand as shown in Figure 10. Using
your index finger, squeeze the link
toward the top of the hand tool frame.
This will release the preload
adjustment wheel.
2. Rotate the setting wheel
counterclockwise (CCW) to increase
handle force. The numbers will display
higher. To decrease handle force,
rotate the setting wheel clockwise
(CW).
3. Release the link to lock the setting
wheel in place.
4. Check the crimp specifications or
conduct a pull test after tool handle
preload force is adjusted.
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: Molex crimp specifications are valid only when used with Molex terminals and tooling.
RATCHET RELEASE
LEVER
Figur 10

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal
Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 6 of 7
Revision: Revision Date: 05-24-17
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.
C rtification
Molex does not certify or re-certify 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 that has been stripped 12.7mm
(.50”) long so that 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.
% If the tool does not meet minimum pull force values, handle preload should be increased, and the pull test
should be rerun (see How to Adjust Preload).
% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.

Hand Crimp Tool for 1.25mm (.049") Pitch Wire-to- oard Crimp Terminal
Doc No: 638275000 Release Date: 04-27-15 UNCONTROLLED COPY Page 7 of 7
Revision: Revision Date: 05-24-17
PARTS LIST
It m Numb r
Ord r Numb r
D scription
Quantity
REF
638
2
7
-
50
00
Hand Crimp Tool
Figure 13
1
638
2
7
-
50
75
Locator Assembly
1
2
63810
-
0104
Spring, Return
1
3
63810
-
0105
Spring, Ratchet
1
Application Tooling Support
Phon : (402) 458-TOOL (8665)
E-Mail: [email protected]
W bsit : 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.
2
1
3
RATCHET
RELEASE LEVER
Figur 13