molex 63827-9300 User manual

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 1 of 7
Revision: B Revision Date: 02-08-21
BELL MOUTH
WIRE
INSULATION
CONTACT GAP
0.00mm - 0.05mm
SEAM
3.75mm 0.20
3.75mm 0.20
CONTACT GAP
1.00mm

.20
BEND
DOWN
TWISTIN
G
ROLLING
BEND
UP
CONDUCTOR
BRUSH
STRIP
LENGTH
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
INSULATION
CRIMP
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
This tool is IPC/WHMA-A-620 Class 2 compliant
When crimping to AWG type wires, use tool 63811-1500 or 63811-1600
SCOPE
Products: Mini-Fit Sr. Male and Female Terminals crimped to 5mm2and 6mm2wire.
Terminal
Series No.
Terminal
Order No. (3)
Wire Size
Insulation Diameter
Strip Length
IPC/WHMA-A-620 (1)
Terminal (2)
mm²
Construction
mm
In.
mm
In.
mm
In.
42815
42815-0010
42815-0012
42815-0011
42815-0019
6
37 x 0.45mm
4.00-4.20
.157-.165
3.50-5.30
0.14-0.21
7.50-8.50
0.30-0.36
6
84 x 0.29mm
5
65 x 0.32mm
42817
42817-0010
42817-0012
42817-0110
42817-0112
42817-0011
42817-0019
42817-0111
6
37 x 0.45mm
4.00-4.20
.157-.165
3.50-5.30
0.14-0.21
7.50-8.50
0.30-0.36
6
84 x 0.29mm
5
65 x 0.32mm
(1) To achieve optimum IPC/WHMA-A-620 insulation crimps, use this insulation OD range
(2) Overall insulation OD specification for terminal.
(3) Reeled terminals: When cutting terminal from strip, cut-off tab not to exceed 0.50mm (.020”)
DEFINITION OF TERMS
TYPE 4E
Order Number
63827-9300

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: 02-08-21
CRIMP SPECIFICATION
Terminal Series No.
Bell Mouth
Conductor Brush
mm
In.
mm
In.
42815
42817
0.20-0.50
.008-.020
3.50-4.50
.140-.180
Terminal Series No.
Bend Up
Bend Down
Twist
Roll
Seam
Degrees Max.
Degrees Max.
42815
42817
3
3
4
8
Seam shall not be
open and no wire allowed
out of the crimping area
After crimping, the crimp profiles should measure the following:
Terminal
Series No.
Wire Size
Conductor Crimp
Insulation Crimp
Pull Force
Minimum
Profile
Height (Ref)
Width
(Ref)
Width (Ref)
mm2
mm
In.
mm
In.
mm
In.
N
Lb.
5
6
42815
5
2.97-3.07
.117-.121
3.95
.155
5.60
0.22
290
65
X
6
3.10-3.30
.122-.130
4.00
.157
5.10
0.20
320
72
X
42817
5
2.97-3.07
.117-.121
3.95
.155
5.60
0.22
290
65
X
6
3.10-3.30
.122-.130
4.00
.157
5.10
0.20
320
72
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.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects
as damage can occur to the tool frame or crimping die.
Note
A crimp height chart is provided with this manual as reference only. Because 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.

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: 02-08-21
TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE
LOCATOR
Figure 3
PRE-STRIPPED
WIRE
TERMINAL
RELEASE THE
LEVER
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. See Figure 1.
Crimping Terminals
1. Select the desired terminal listed in the
preceding charts.
2. Push the wire stop lever on the side of the
hand tool to raise the wire stop up before
inserting the terminal in the hand tool. See
Figure 2.
3. With the wire stop lever pushed in, load the
terminal into the proper nest opening marked
with the wire gauge on the hand tool. See
Figure 2.
4. Next release the wire stop lever, allowing the
wire stop to return to the crimping position.
5. Insert the properly stripped wire through the
terminal and against the wire stop. See Figure
3.
6. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been
completed. Release the handles to open the jaws. See Figure 4.
Note: The tamper-proof ratchet action will not release the tool until it has been fully closed.
7. Push the wire stop lever in to raise the wire stop up and remove
the crimped terminal from the locator by lifting up and then pulling
the wire out.
8. Visually inspect the crimped terminal for proper crimp location.
HANDLES
OPEN
Figure 1
INSERT
TEMINAL
PUSH
LEVER TO
RAISE WIRE
STOP
Figure 2
SQUEEZE
HANDLES
TOGETHER
LEVER
UP
Figure 4

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: 02-08-21
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 and turn the tool upside down on the back side.
2. Remove the tightening lock nut.
3. Remove the locator assembly from the frame head.
4. To reinstall the new locator, make sure the hand tool is in the open position.
5. Replace the locator assembly into the frame head.
6. Reinstall the tightening lock nut.
Remove and Install Tooling
1. Make sure the tool is in open position before removing or installing tooling.
2. The locator must be removed before removing or installing tooling.
3. Remove the M4 screw that is holding the upper tooling.
4. Remove or install upper tooling through the back side of the tool frame.
5. Install the M4 screw. Make sure the small markings on the front of the hand tool frame
match up. See Figure 5.
6. Follow steps 3-5 for the lower tooling except through the
front side of the tool frame and install the M3 screw. Be
sure the small markings on the lower tooling line up
with upper tooling.
7. Slowly close the tool handles to align upper and lower
tooling together. Tighten the M4 screws and continue
squeezing the tool handles until the hand tool swings
open.
8. 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: See Figure 6.
1. Un-snap the 2 Snap-On plastic covers (front and back).
2. Remove dust, moisture and other contaminants with a clean
brush or a soft, lint-free cloth.
3. Do not use any abrasive materials that could damage the tool.
4. 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 1,000 crimps or 3
months will significantly enhance the tool life.
5. 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.
6. 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 1,000 CRIMPS)
Figure 6
MATCH
UP MARKS
Figure 5
MATCH
UP MARKS
M4 SCREWS

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: 02-08-21
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 using a small flat screwdriver
pressing up on the ratchet release lever in the movable
handle. The handle should be partially closed.
See Figure 7.
HOW TO ADJUST TOOL PRELOAD (SEE FIGURE 8)
This hand tool is factory preset to 210 N (47 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. Open the tool by squeezing the handles together
until the ratchet mechanism release, the hand
tool handles will spring open.
2. Remove the M3 screw and the M3 washer.
3. Lift the setting wheel off the axle. Use a small flat
head screwdriver to turn the eccentric axle
counterclockwise (CCW) to increase handle force.
4. To decrease handle force, turn the eccentric axle
clockwise (CW).
5. Line up the setting wheel matching the flat side
with the flat edge of the axle so the wheel notch
will drop onto the roll pin. The numbers will
display higher.
6. Re-install the M3 washer and M3 screw.
7. Re-crimp a new sample and 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.
Figure 7
SMALL
FLAT HEAD
SCREWDRIVER
HANDLES SHOULD BE
PARTIALLY CLOSED
RATCHET
RELEASE LEVER
Figure 8
FLAT HEAD
SCREWDRIVER
M3 x 6 LONG
SCREW
RATCHET
RELEASE
LEVER
RATCHET
RELEASE LEVER
WASHER
SETTING
WHEEL
ECCENTRIC AXLE

Hand Crimp Tool Quick Disconnect, Female Crimp Terminals
Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 6 of 7
Revision: B Revision Date: 02-08-21
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.
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. 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 Quick Disconnect, Female Crimp Terminals
Doc No: ATS-638279300 Release Date: 12-02-15 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: 02-08-21
Figure 9
1
2
M4 x 12 LG SCREW
M4 x 30 LG SCREW
M4 LOCKNUT
M3 x 6 LG SCREW
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63827-9300
Hand Crimp Tool
Figure 9
1
63827-9375
Locator Assembly
1
2
63810-0105
Spring, Ratchet
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.