molex 63827-8800 User manual

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 06-04-15
INSULATION
CRIMP ▲
STRIP LENGTH
CONDUCTOR
CRIMP HEIGHT
CUT-OFF
TAB
SEAM
BELL MOUTH
WIRE
CONDUCTOR
BRUSH
BEND UP
TWISTING
ROLLING
BEND
DOWN
Application Tooling
Specification Sheet
Tool Kit
Order No. 63827-8870
Hand Crimp Tool
Order No. 63827-8800
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomically designed soft handles
Precisely designed crimping profiles with simple contact positioning
Easy handling due to outstanding force ratio
Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
Many different Tool kits can be used with a single Battery Powered Tool.
This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
SCOPE
Products: Single Contact Terminal for S8 and T20 Socket
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
IPC/WHMA-A620 (1)
Terminal Insulation
Maximum (2)
Reel Form Only (3)
mm²
Type
mm
In.
mm
In.
mm
In.
49869
49869-9102
0.50
AVS
2.0 –2.1
0.078 –0.083
2.2
0.087
5.0 –5.5
0.20 –0.22
0.75
FLRY-A
1.7 –1.9
0.067 –0.075
0.85
AVS
2.1 –2.3
0.083 –0.091
(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
(3) The terminals above are reeled parts only. Customer to cut off terminal from reel: 0.30 mm (.012”) maximum
DEFINITION OF TERMS
TYPE 4C

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 06-04-15
▲Insulation Crimp Note:
Due to the terminal’s insulation grip design
and/or insulation diameter range, this tool
uses “overlap” form geometry in the
insulation punch. This produces an overlap
insulation crimp (A620 –compliant). While
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 (See notes below).
Terminal Series No.
Bell mouth
Conductor Brush
Bend up Bend Down
Twist Roll
mm
In.
mm
In.
Degrees Max.
Degrees Max.
49869
0.30 –0.60
.012 –0.024
0.30 –0.80
.012 –0.031
3
3
3
5
Terminal Series No.
Wire Size
Conductor Crimp
Profile
Height
Width (Ref)
mm²
mm
In.
mm
In.
A
B
C
49869
0.50
1.35 –1.45
0.053 –0.057
2.10 –2.20
0.083 –0.087
X
0.75
1.45 –1.50
0.057 –0.059
X
0.85
1.45 –1.55
0.057 –0.061
X
Terminal Series No.
Wire Size
Insulation Crimp
Pull Force Minimum
Height (Ref)
Width (Ref)
mm2
mm
In.
mm
In.
N
Lbs
49869
0.50
2.8
0.110
2.5
0.098
88.3
20
0.75
2.9
0.114
2.7
0.106
117.8
26.5
0.85
3.0
0.118
3.0
0.118
127.5
28.7
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 manual as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the
minimum pull force specifications listed.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 06-04-15
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the
nest. Install the M4 x 10 long BHCS and tighten
in place.
2. Insert the Punches into the top slots of the nest.
Install the M4 x 18 long BHCS and tighten in
place. See Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the
locator. See Figure 2.
To install the locator
1. Position the locator with the hole over the brass pivot shaft and snap it into place.
To remove the locator
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
3. Firmly press down on the brass pivot shaft with your thumb,
while pulling the locator up. Slip the locator off the top of the
brass pivot shaft.
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.
Crimping Terminals
1. Crimp only the terminal listed in the preceding charts.
2. Turn the Locator Lock Latch down to unlock. See Figure 3.
3. Swing the terminal locator away from the crimp tool
shown in Figure 4. Some terminals with large
insulation grips may interfere with the crimp tooling
when swinging the locator into position. The terminal
must then be loaded into the locator in the closed/crimp
position. See Figure 5.
4. Press down on the wire stop on the locator as shown in
Figure1. Insert the terminal into the proper nest
opening. Make sure when choosing the nest opening,
it will correspond with the A, B or C profile on the hand
tool.
5. Return the locator to its original position.
6. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.
Figure 3
LATCH LOCKED
LATCH UNLOCKED

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 06-04-15
Figure 6
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Figure 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
TERMINAL
IN PLACE
Figure 4
LOCATOR LATCH
IN OPEN POSITION
Figure 7
WIRE
INSULATION
PUNCH
CONDUCTOR
ANVIL
LOCATOR
INSULATION ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
7. Insert the proper wire over the terminal.
8. Gently touch the wire stop with the end of the wire. See Figure 6 and 7.
9. Crimp the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
10. Remove the crimped terminal from the terminal
locator by pressing down on the wire stop and
gently pulling on the wire. The terminal locator can
be in either position.
11. Visually inspect the crimped terminal for proper
crimp location.
Note: The tamper proof ratchet action will not release
the tool until it has been fully closed.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal
to the wire.
2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
3. Visually inspect the crimped terminal for proper crimp location.

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 06-04-15
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 in the tool head are
protected with a thin coat of high quality
machine oil. Do not oil excessively. This
tool was engineered for durability, but like any fine piece of equipment, it needs cleaning and lubrication for a
maximum service life of trouble-free crimping. The use of light oil, such as 30 weight automotive oil, every
5,000 crimps or monthly, will significantly enhance the tool life and ensure a stable calibration. See Figure 8A
or 8B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams (for Manual Tools Only) (See Figure 11)
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 rotating the small slotted screw marked with an arrow. See Figure 11.
Warranty
This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange
will not be applicable to altered, misused, or damaged tools.
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.
CAUTION: Repetitive use of this tool should be avoided.
Certification
Molex does not certify or re-certify commercial grade 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
WIRE
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 8A
Figure 8B

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 06-04-15
25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull
testing.
When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.
This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
Adapter
Description
Figure
No.
63827-8870
63810-1050
Hand Crimp Frame (Short)
N/A
N/A
9
63810-1000
Hand Crimp Frame (Long)
N/A
N/A
9
63816-0200
Battery Power Tool (110 V)
63816-0300
Power Crimp Head
10
63816-0250
Battery Power Tool (220 V)
63816-0300
Power Crimp Head
10
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure 9
Figure 10
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper Manual or
Specification Sheet. See Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the
power is turned off.
CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.
CAUTION: Wear safety glasses when operating or serving this tool.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 06-04-15
RATCHET
RELEASE SCREW
Figure 11
M4 X 8mm
LONG BHCS
2
1
1
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
3
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810-1000
Hand Crimp Frame (Long)
1
2
63827-8870
Tool Kit with Locator
1
3
63827-8875
Locator (only)
REF

Hand Crimp Tool for Single Contact Terminal
Doc No: ATS-6382788HM Release Date: 06-04-15 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 06-04-15
Figure 12
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63816-0300
63816-0300
Power Crimp Head
1
2
63827-8870
63827-8870
Tool Kit with Locator
1
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