molex 63827-7900 User manual

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 02-03-15
INSULATION CRIMP
BRUSH
STRIP LENGTH
CONDUCTOR
CRIMP HEIGHT
CUT-OFF TAB
SEAM
BELL MOUTH
WIRE
CUT-OFF TAB
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
Order No. 63827-7900
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomic soft grip handles for comfortable crimping
A precision user-friendly terminal locator wire stop holds terminals in the proper crimping position
Right and Left handed applications
Dies and Locator from this tool can be used in the Battery 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 Battery Powered Crimp Tool
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 6.35mm Slip-On Receptacle, 22 - 20 AWG.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Reel
AWG
mm²
mm
In.
mm
In.
35725
35725-3800
22-20
0.35-0.50
2.6 max
.102 max
4.80-5.20
.157-.205
35725-3801
35725-3810
Customer to cut off terminal from reel: Cut tabs flush with terminal at both ends.
DEFINITION OF TERMS
TYPE 4D

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 02-03-15
CONDITIONS:
After crimping, the conductor profiles should measure the following. See Notes below.
Terminal Series No.
Wire Size
Conductor Crimp
Profile
Height (Ref.)
Width (Ref.)
AWG
mm2
mm
In.
mm
In.
22
20
35725
22
0.35
1.10-1.30
.043-.051
2.10-2.30
.083-.091
X
20
0.50
1.20-1.40
.047-.055
2.10-2.30
.083-.091
X
Terminal Series No.
Wire Size
Insulation Crimp
Pull Force Minimum
Width (Ref.)
AWG
mm2
mm
In.
N
Lb.
35725
22
0.35
2.80-3.00
.110-.118
58.8
13.2
20
0.50
2.80-3.00
.110-.118
78.4
17.6
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 document as Reference Only. Due to 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 as
damage can occur to the tool frame
and/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 Terminals
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.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 02-03-15
RELEASE
LOCATOR BUTTON
TERMINAL
Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
PRE-STRIPPED WIRE
TERMINAL
WIRE AGAINST THE
WIRE STOP
Figure 5
TERMINAL
WIRE
WIRE STOP IS PART
OF THE LOCATOR
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.
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 through the terminal and against the
wire stop. 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.
Note: 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 proper crimp location.
10. On some large O.D. wires, it may not be possible to insert the wire
with the tool partially closed. Those wires should be inserted with
the hand tool in the open position. Insert the wire above the
terminal in the punch and against the wire stop then close the tool.
See Figure 6.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
TERMINAL
Figure 6
WIRE
WIRE
STOP

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 02-03-15
Figure 9
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Figure 8
Locator Replacement
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 7A 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 7A.
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 7B.
6. Holding onto the lower part of the locator
with your thumb and index finger, insert the locators top hooks (2) into the hand tool 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.
Right or Left Hand Operation
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 BHCS which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side and
replace the M3 BHCS. 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 Figure 8 and 9.
4. Do the same thing with the lower tooling and
tighten the M3 screws. Be sure the small
markings line up.
5. Reinstall the locator by following the Instructions
in the locator replacement section.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 02-03-15
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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 pressing up on the ratchet release
lever in the movable handle. See Figure 11.
How to Adjust Tool Preload
(See Figure 12)
This hand tool is factory preset to 25-45
LBS. 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 12. Using
the index finger squeeze the link
towards the top of the hand tool frame.
This will release the preload
adjustment wheel.
2. Rotate the setting wheel counter-clockwise (CCW) to increase handle force. The numbers will display higher.
To decrease handle force rotate the setting wheel clockwise (CW).
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11

Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 02-03-15
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, 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: 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.
Certification
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, 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 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
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 6.35mm Slip-On Receptacle Terminals.
Doc No: ATS-638277900 Release Date: 02-03-15 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 02-03-15
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63827-7900
Hand Crimp Tool
Figure 13
1
63827-7975
Locator Assembly
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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