Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
HAND CRIMP
TOOL
Application Tooling
Specification Sheet
TYPE 4D
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 Order No.
Wire Size
Insulation Diameter
Strip Length
Reel
AWG
mm²
mm
In.
mm
In.
35725-3800
35725
35725-3801
22-20 0.35-0.50 2.6 max .102 max 4.80-5.20 .157-.205
35725-3810
Customer to cut off terminal from reel: Cut tabs flush with terminal at both ends.
Terminal Series No.
DEFINITION OF TERMS
CONDUCTOR
CRIMP HEIGHT
INSULATION CRIMP
WIRE
SEAM
STRIP LENGTH
BELL MOUTH
BRUSH
CUT-OFF TAB
CUT-OFF TAB
Doc No: ATS-638277900
Revision: A
Release Date: 02-03-15
Revision Date: 02-03-15
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Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
CONDITIONS:
After crimping, the conductor profiles should measure the following. See Notes below.
Terminal Series No.
35725
Conductor Crimp
Profile
Height (Ref.)
Width (Ref.)
AWG mm2
mm
In.
mm
In.
22 20
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
Wire Size
Terminal Series No.
35725
Insulation Crimp
Pull Force Minimum
Width (Ref.)
AWG mm2
mm
In.
N
Lb.
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
Wire Size
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.
LOCATOR
IN DOWN
POSTION
HANDLE WILL
SPRING OPEN
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.
Figure 1
SQUEEZE
HANDLES
TOGETHER
Figure 2
PUSH ON THE
LOCATOR BUTTON
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.
Doc No: ATS-638277900
Revision: A
Release Date: 02-03-15
Revision Date: 02-03-15
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Page 2 of 7
Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
LOCATOR
PUSHED THRU
TOOLING
RELEASE
LOCATOR BUTTON
TERMINAL
LOCATOR
BUTTON
PUSHED IN
Figure 3
TERMINAL
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.
WIRE AGAINST THE
WIRE STOP
TOOLING
PARTIALLY
CLOSED
PARTIALLY
CLOSE HANDLE
OPEN
POSITION
FIRST RATCHET
POSITION
WIRE STOP IS PART
OF THE LOCATOR
Figure 4
TERMINAL
WIRE
PRE-STRIPPED WIRE
Figure 5
TERMINAL
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.
WIRE
WIRE
STOP
TERMINAL
Figure 6
Doc No: ATS-638277900
Revision: A
Release Date: 02-03-15
Revision Date: 02-03-15
UNCONTROLLED COPY
Page 3 of 7
Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
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.
LOCATOR
SQUEEZE
HERE
SQUEEZE
HERE
Figure 7A
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
1. Open the crimp hand tool.
TOP SLOTS OF
2. Squeeze gently on the lower area shown in
HANDTOOL
Figure 7A with your thumb and index finger.
The lower tabs of the locator should
TOP HOOKS
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.
LOWER TABS
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
MATCH
secure the locator into place, the lower tabs must
UP MARKS
snap into place on the hand tool frame.
Right or Left Hand Operation
Figure 8
This hand tool has an added feature that can be
converted from a right handed application to a left
FRONT
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.
Doc No: ATS-638277900
Revision: A
Release Date: 02-03-15
Revision Date: 02-03-15
Figure 7B
BACK
JAWS OPEN
TOOLING
PULL OPEN
TOOLING
M3 BHCS
Figure 9
PUSH ON
HANDLE
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Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Miscrimps or Jams
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 pressing up on the ratchet release
lever in the movable handle. See Figure 11.
How to Adjust Tool Preload
(See Figure 12)
RATCHET
RELEASE LEVER
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
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
Figure 12
hand as shown in Figure 12. Using
the index finger squeeze the link
SETTING
towards the top of the hand tool frame.
WHEEL
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).
Doc No: ATS-638277900
Revision: A
Release Date: 02-03-15
Revision Date: 02-03-15
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Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
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.
Doc No: ATS-638277900
Revision: A
Release Date: 02-03-15
Revision Date: 02-03-15
UNCONTROLLED COPY
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Hand Crimp Tool For 6.35mm Slip-On Receptacle Terminals.
PARTS LIST
Item Number
REF
1
2
3
Order Number
63827-7900
63827-7975
63810-0104
63810-0105
Description
Hand Crimp Tool
Locator Assembly
Spring, Return
Spring, Ratchet
Quantity
Figure 13
1
1
1
2
1
Figure 13
3
Visit our Web site at http://www.molex.com
Doc No: ATS-638277900
Revision: A
Release Date: 02-03-15
Revision Date: 02-03-15
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