molex 63827-8600 User manual

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 1 of 8
Revision: B Revision Date: 08-20-19
INSULATION
CRIMP
BRUSH
STRIP LENGTH
BELL MOUTH
CONDUCTOR
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLL
WIRE
TWIST
CUT-OFF
TAB
SEAM
Application Tooling Specification
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. 63816-0270
(110 V) or 63816-0280 (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 IPC/WHMA-A-620 Class 2 compliant (see page 2)
This tool is RoHS compliant; however, RoHS compliance is not required
SCOPE
Products: Ditto Wing Genderless Interconnects Terminal, 24–26 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
▲IPC/WHMA-A-620 (1)
Terminal (2)
Reel
AWG
mm
In.
mm
In.
mm
In.
150197
150197-0002
24-26
0.80-1.55
.031-.061
1.05-1.50
.041-.059
2.30-2.80
.090-.110
150200
150200-0002
150200-0012
24-26
0.80-1.55
.031-.061
1.05-1.50
.041-.059
2.30-2.80
.090-.110
(1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
DEFINITION OF TERMS
Order Number
63827-8600
Type 4D

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 2 of 8
Revision: B Revision Date: 08-20-19
▲Insulation Crimp Note
Due to the terminal’s insulation grip design
and insulation diameter range, this tool uses
overlap form geometry in the insulation
punch. This produces an overlap insulation
crimp (A-620 compliant). Although 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:
Terminal Series No
Wire Size
Conductor Crimp
Height
Width
AWG
mm
In.
mm
In.
150197
150200
24
0.95–1.05
.037-.041
1.40-1.50
.055-.059
26
0.95–1.00
.037-.039
Terminal
Series No
Wire Size
Insulation Crimp Maximum
Pull Force
Minimum
Profile
Height (Ref.)
Width (Ref.)
A
B
C
D
AWG
mm
In.
mm
In.
N
Lb.
26
24
24
26
150197
150200
24
1.75-1.85
.069-.073
1.75-1.85
.069-.073
26.7
6.0
X
1.55-1.65
.061-.065
1.55-1.65
.061-.065
X
26
1.75-1.85
.069-.073
1.75-1.85
.069-.073
17.8
4.0
X
1.50-1.60
.059-.063
1.40-1.50
.055-.059
X
▲To achieve IPC/WHMA-A-620 Class 2 crimps, the following overall wire insulation diameter ranges are recommended:
Profile A: 1.30-1.40mm (.051-.055”) Profile C: 1.10-1.20mm (.043-.047”)
Profile B: 1.35-1.55mm (.053-.061”) Profile D: 0.80-1.00mm (.031-.039”)
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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 3 of 8
Revision: B Revision Date: 08-20-19
Figure 5
TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE-STRIPPED
WIRE
TERMINAL
RELEASE
LOCATOR BUTTON
TERMINAL
Figure 3
LOCATOR
PUSHED
THROUGH
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
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 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 from the preceding charts and
install it in the proper locator (See chart above and see Locator
Replacement on page 4).
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 in the locator button, 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.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST RATCHET
POSITION
OPEN
POSITION
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 4 of 8
Revision: B Revision Date: 08-20-19
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, and then close
the tool. See Figure 6.
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 hand crimp 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 locator 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.
TERMINAL
Figure 6
WIRE
WIRE
STOP
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE DOWN
POSITION
Figure 7B

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 5 of 8
Revision: B Revision Date: 08-20-19
Right- or Left-Handed 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 Figures
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.
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. See Figure
10. 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 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.
MATCH
UP MARKS
FRONT
BACK
Figure 9
LUBRICATION POINTS
(BOTH SIDES) LIGHT
OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
Figure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 6 of 8
Revision: B Revision Date: 08-20-19
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 pounds handle 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 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.
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.
RATCHET RELEASE
LEVER
Figure 11
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER

Hand Crimp Tool for Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 7 of 8
Revision: B Revision Date: 08-20-19
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 that has been
stripped 12.7mm (.500”) 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 Ditto Wing Genderless Interconnects Terminals
Doc No: ATS-638278600 Release Date: 09-29-15 UNCONTROLLED COPY Page 8 of 8
Revision: B Revision Date: 08-20-19
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63827-8600
Hand Crimp Tool
Figure 13
1
63827-8675
Locator Assembly (Red)
1
2
63810-0104
Spring, Return
1
3
63810-0105
Spring, Ratchet
1
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.