molex 63827-2000 User manual

Hand Crimp Tool for.187 Slip on QD Receptacle Terminals
Doc No: ATS-638272000 Release Date: 07-09-15 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 07-09-15
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. 63827-2000
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
This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: .187 Slip on QD Receptacle Terminals, 16-20 AWG UL1015 Wires.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
IPC/WHMA-A620 (1)
Terminal (2)
Insulation range
AWG
mm²
mm
In.
mm
In.
mm
In.
35718
35718-0800
35718-0810
16-20
NA
2.60-3.20
.102-.126
2.50-3.50
.098-.138
4.40-5.00
.173-.197
35718-0900
35718-0910
35718-1000
35718-1010
Note: This terminal will accommodate the UL1015 Wires.
(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
(3) Customer to cut off terminal from reel: 0.40mm (.016”) maximum cut-off tab (both ends).
DEFINITION OF TERMS
TYPE 4E

Hand Crimp Tool for.187 Slip on QD Receptacle Terminals
Doc No: ATS-638272000 Release Date: 07-09-15 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 07-09-15
CRIMP SPECIFICATIONS
Terminal Series No.
Bell mouth
Conductor Brush
mm
In.
mm
In.
35718
0.25-0.50
.010-.020
0.50-1.00
.020-.039
Terminal Series No.
Bend up Bend down
Twist Roll
Seam
Seam shall not be
open and no wire allowed
out of the crimping area
Degree Max.
Degree Max.
35718
3
3
3
5
After crimping, the crimp profiles should measure the following:
Terminal Series No.
Wire Size
Conductor Crimp
Profile
Height
Width
AWG
mm2
mm
In.
mm
In.
A
B
C
18 AWG
16 AWG
20 AWG
35718
16
NA
1.45-1.55
.057-.061
2.40-2.60
.094-.102
X
18
NA
1.30-1.40
.051-.055
2.40-2.60
.094-.102
X
20
NA
1.20-1.30
.047-.051
2.40-2.60
.094-.102
X
Terminal Series No.
Wire Size
Insulation Crimp
Pull Force Minimum
Height (Max.)
Width (Max.)
AWG
mm2
mm
In.
mm
In.
N
Lb.
35718
16
NA
4.00
.157
3.60
.142
127.4
28.7
18
NA
3.60
.142
3.50
.138
107.8
24.3
20
NA
3.40
.134
3.40
.134
58.8
13.2
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 or die.
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 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 for.187 Slip on QD Receptacle Terminals
Doc No: ATS-638272000 Release Date: 07-09-15 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 07-09-15
Figure 3
PRE-STRIPPED
WIRE
TERMINAL
TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE
WIRE
STOP
PRESS TO
FLIP UP THE
WIRE STOP
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. Press the wire stop lever to lift up the wire stop.
3. Load the terminal into the proper nest opening
marked with the wire gauge on the hand tool,
then lower the wire stop. See Figure 2.
4. Insert the properly stripped wire through the terminal and against the wire stop which is part of the locator.
See Figure 3.
5. Crimp the terminal by squeezing the tool handles until the handles are fully closed. Release the handles to
open the jaws.
Lift up the wire stop and remove the crimped terminal from the tool.
See Figure 4.
Note: The tamper proof ratchet action will not release the tool until it has been
fully closed
6. Visually inspect the crimped terminal for proper crimp condition.
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 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.
HANDLES
OPEN
Figure 1
INSERT
TEMINAL
Figure 2
SQUEEZE
HANDLES
TOGETHER
Figure 4

Hand Crimp Tool for.187 Slip on QD Receptacle Terminals
Doc No: ATS-638272000 Release Date: 07-09-15 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 07-09-15
MATCH
UP MARKS
Figure 5
MATCH
UP MARKS
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 remove or install tooling.
2. The locator must be removed before remove or install tooling.
3. Remove the M3 screw which is holding the upper tooling.
4. Remove or install upper tooling through the back side of the tool frame.
5. Install the M3 screw. Make sure the small markings on the front of the hand tool frame match up. See
Figure 5.
6. Follow step 3 to 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 M3 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 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.
Figure 7
SMALL
FLAT HEAD
SCREWDRIVER
HANDLES SHOULD BE
PARTIALLY CLOSED
RATCHET
RELEASE LEVER
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY 3 MONTHS
OR 1,000 CRIMPS)
Figure 6

Hand Crimp Tool for.187 Slip on QD Receptacle Terminals
Doc No: ATS-638272000 Release Date: 07-09-15 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 07-09-15
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
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. 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 counter-clockwise (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, 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.
Figure 8
FLAT HEAD
SCREWDRIVER
M3 x 6 LONG
SCREW
RATCHET
RELEASE
LEVER
RATCHET
RELEASE LEVER
WASHER
SETTING
WHEEL
ECCENTRIC AXLE

Hand Crimp Tool for.187 Slip on QD Receptacle Terminals
Doc No: ATS-638272000 Release Date: 07-09-15 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 07-09-15
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. 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.187 Slip on QD Receptacle Terminals
Doc No: ATS-638272000 Release Date: 07-09-15 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 07-09-15
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
63827-2000
Hand Crimp Tool
Figure 9
1
63827-2075
Locator Assembly
1
2
63810-0106
Spring, Ratchet
1
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