molex 63825-0500 User manual

Hand Crimp Tool for Commoning Crimp Terminals
Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Da e: 02-14-11
BRUSH
STRIP
LENGTH
BELL MOUTH
CONDUCTOR
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT-OFF TAB
SEAM
INSULATION
CRIMP
TYPE 4D
HAND CRIMP
TOOL
Application Toolin
Specification Sheet Order No. 63825-0500
FEATURES
 A full cycle ra che ing hand ool ensures comple e crimps
 Ergonomic sof grip handles for comfor able crimping
 A precision user-friendly erminal loca or wire s op holds erminals in he proper crimping posi ion
 Righ and Lef handed applica ions
 This ool is WHMA-IPCA620 Class 2 complian as indica ed
 This ool is RoHS complian , however RoHS complian is no required
SCOPE
Produc s: Commoning Terminals, 28-30 AWG.
Terminal
Series No.
Terminal Order No.  Wire Size
%
Insulation Diameter Strip Len th
Loose Piece
+
Reel
AWG
mm²
mm
In.
mm
In.
1457
-
6
05
-
02
-
00
92
05
-
02
-
00
91
2
8
-
30
0.
09
-
.055
0.90
-
0
.
80
.0
35
-
.
03
1
3.
96
-
5.54
.1
56
-
.
218
+
Cus omer o cu off erminal from reel: 0.18mm (.007”) maximum Cu
-
off Tab.
%
To Achieve IPC-A-620 Class 2 Crimps, the followin wire insulation diameter limits are recommended:
1. 28 AWG 0.89mm (.035 inch) UL1061.
2. 30 AWG 0.81mm (.032 inch) UL1061.
 For Crimping 24-26 AWG Wire- Use 63823-1200 Hand Crimp Tool.
DEFINITION OF TERMS

Hand Crimp Tool for Commoning Crimp Terminals
Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Da e: 02-14-11
LOCATOR IN
DOWN POSTION
PUSH
ON THE
LOCATOR BUTTON
Fi ure 2
▲Insulation Crimp Note:
Due o he erminal’s insula ion grip design
and/or insula ion diame er range, his ool
uses “overlap” form geome ry in he
insula ion punch. This produces an overlap
insula ion crimp (A620 – complian ). While
he insula ion punch profile may appear
“lopsided”, his is a normal condi ion for his
ool. See figure o he righ . (Some ools
wi h mul iple crimp pocke s may no have
he “overlap” profile on all pocke s).
CONDITIONS:
Af er crimping, he conduc or profiles should measure he following.
Terminal Series No
Wire Size
Conductor Cri
mp
Insulation Crimp
AWG
mm
2
Hei ht (Ref.)
Width (Ref.)
Hei ht (Ref.)
Width (Ref.)
1457-6
28
0.09
0.89
-
0.91
.035
-
.036
1.
10
.0
43
1.65 Max
.
065 Max.
1.55
.061
30
0.
055
0.
86
-
0.89
.034
-
.035
1.
10
.0
43
1.65 Max
.
065 Max.
1.35
.053
Terminal Series No Wire Size
Pull Force
Minimum Profile
AWG
mm
2
N
Lb.
2
8
30
1457-6
2
8
0.
09
11.2
2
.5
X
30
0.
055
4.4
1
.0
X
Tool Qualifica ion No es:
1. Pull Force should be measured wi h no influence from he insula ion crimp.
2. The above specifica ions are guidelines o an op imum crimp.
OPERATION
CAUTION: Ins all only Molex erminals lis ed above wi h his ool. Do no crimp
hardened objec s as damage can occur o he ool or die.
Open he ool by squeezing he handles oge her. A he
end of he closing s roke, he ra che mechanism will
release he handles and he hand ool will spring open.
See Figure 1.
Crimpin Terminals
1. Selec he desired erminal, lis ed in he preceding
char s. Ins all he proper loca or (See char above
and see Loca or Ins alla ion on page 5).
2. Make sure he cen er of he loca or is in he down
posi ion. Wi h he loca or a ached, push he loca or bu on on he back of he
hand ool o bring he loca or forward hrough he ooling. See Figure 2.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Fi ure 1
OVERLAP
INSULATION
CRIMP
OVERLAP
FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool for Commoning Crimp Terminals
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Revision: A Revision Da e: 02-14-11
TERMINAL
Fi ure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
RELEASE
LOCATOR
BUTTON
LOCATOR
BUTTON
PUSHED IN
PRE
-
STRIPPED
WIRE
TERMINAL
Fi ure 5
TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP
IS PART OF
THE LOCATOR
3. While holding in he loca or bu on, load he erminal in o he proper nes
opening in he loca or based on he wire gauge or erminal ype
markings on he hand ooling. See Figure 3.
4. Release he loca or bu on, allowing he loca or o re urn o he crimping
posi ion.
5. Close he ool handle un il he firs ra che posi ion engages. See Figure
4.
6. Inser he properly s ripped wire hrough he erminal and agains he
wire s op. See Figure 5.
7. Crimp he erminal by squeezing he ool handles un il he ra che
mechanism cycle has been comple ed. Release he handles o open
he jaws.
No e: The amper proof ra che ac ion will no release he ool un il i has been fully closed.
8. Remove he crimped erminal from he erminal
loca or by pulling on he wire.
9. Visually inspec he crimped erminal for proper
crimp loca ion.
10. On some large O.D. wires, i may no be possible o
inser he wire wi h he ool par ially closed. Those
wires should be inser ed wi h he hand ool in he
open posi ion. Inser he wire above he erminal in
he punch and agains he wire s op hen close he
ool. See Figure 6.
TERMINAL
Fi ure 6
WIRE
WIRE STOP
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Fi ure 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool for Commoning Crimp Terminals
Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Da e: 02-14-11
Fi ure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
SQUEEZE
HERE
LOCATOR
Fi ure 7A
SQUEE
ZE
HERE
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Fi ure 7B
Note:
A crimp heigh char is provided wi h his manual as Reference Only. Due o he wide range of wires, s rands,
insula ion diame ers, and durome ers available, ac ual crimp heigh measuremen s may very sligh ly. An
occasional, des ruc ive, pull force es should be preformed o check hand ool crimp. Pull Force value Mus exceed
he Minimum pull force specifica ions lis ed.
Locator Installation
See he par s lis on he las page of his documen for he proper loca or order number. Follow he s eps below o
replace he loca or.
1. Open he crimp hand ool.
2. Squeeze gen ly on he lower area shown in Figure 7A wi h your humb and index finger. The lower abs of he
loca or should disengage from he hand ool.
3. Lif and pull away from he hand ool. The op
loca or hooks should slip ou of he op slo s easily.
See Figure 7A.
4. To reins all he new loca or, make sure he hand
ool is in he open posi ion.
5. Press he red inser down as far as i will go as
shown in Figure 7B.
6. Holding on o he lower par of he loca or wi h your
humb and index finger, inser he loca or op hooks
(2) in o he hand ool op slo s.
7. Ro a e he loca or down and press he lower abs in o he wo bo om slo s of he hand ool. To secure he
loca or in o place, he lower abs mus snap in o place on he hand ool frame.
MATCH
UP MARKS
FRONT
BACK
Fi ure 9

Hand Crimp Tool for Commoning Crimp Terminals
Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Da e: 02-14-11
Ri ht or Left Hand Operation
This hand ool has an added fea ure ha can be conver ed from a righ handed
applica ion o a lef handed applica ion. I is necessary o reverse he ooling
along wi h he loca or if using he lef handed applica ion. Follow he s eps
below:
1. The loca or mus be removed before reversing he ooling.
2. Remove he M3 BHCS which is holding he upper ooling.
3. Flip he upper ooling o he opposi e side and replace he M3 BHCS Make
sure he small markings on he fron and back of he hand ool frame ma ch
up and are on he ou side of he hand ool frame. See Figure 8 and 9.
4. Do he same hing wi h he lower ooling and igh en he M3 screws. Be sure
he small markings line up.
5. Reins all he loca or by following he Ins ruc ions in he loca or replacemen sec ion.
Maintenance
I is recommended ha each opera or of he ool be made aware of, and responsible for, he following main enance
s eps:
1. Remove dus , mois ure, and o her con aminan s wi h a clean brush, or sof , lin free clo h.
2. Do no use any abrasive ma erials ha could damage he ool.
3. Make cer ain all pins; pivo poin s and bearing surfaces are pro ec ed wi h a hin coa of high quali y machine
oil. Do no oil excessively. The ool was engineered for durabili y bu like any o her equipmen i needs
cleaning and lubrica ion for a maximum service life of rouble free crimping. Ligh oil (such as 30 weigh
au omo ive oil) used a he oil poin s, every 5,000 crimps or 3 mon hs, will
significan ly enhance he ool life.
4. Wipe excess oil from hand ool, par icularly from crimping area. Oil
ransferred from he crimping area on o cer ain ermina ions may affec
he elec rical charac eris ics of an applica ion.
5. When ool is no in use, keep he handles closed o preven objec s from
becoming lodged in he crimping dies, and s ore he ool in a clean, dry
area.
Miscrimps or Jams
Should his ool ever become s uck or jammed in a par ially closed posi ion, Do Not force he handles open or
closed. The ool will open easily by pressing up on he ra che release lever in he movable handle. See Figure 11
How to Adjust Tool Preload
(See Fi ure 10)
This hand ool is fac ory prese o 25-45 LBS. preload. I may be necessary over he life of he ool o adjus ool
handle preload force. Lis ed below are he s eps required o adjus he crimping force of he hand ool o ob ain
proper crimp condi ions:
RATCHET RELEASE
LEVER
Fi ure 11
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Fi ure 10

Hand Crimp Tool for Commoning Crimp Terminals
Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Da e: 02-14-11
Fi ure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
1. Hold he hand ool in he palm of your
hand as shown in Figure 12. Using
he index finger squeeze he link
owards he op of he hand ool frame.
This will release he preload
adjus men wheel.
2. Ro a e he se ing wheel coun er-
clockwise (CCW) o increase handle
force. The numbers will display
higher. To decrease handle force,
ro a e he se ing wheel clockwise
(CW).
3. Release he link o lock he se ing
wheel in place.
4. Check he crimp specifica ions or
conduc a pull es af er ool handle
preload force is adjus ed.
Warranty
This ool is for elec rical erminal crimping purposes only. This ool is made of he bes quali y ma erials. All vi al
componen s are long life es ed. All ools are warran ed o be free of manufac uring defec s for a period of 30
days. Should such a defec occur, we will repair or exchange he ool free of charge. This repair or exchange will
no be applicable o al ered, misused, or damaged ools. This ool is designed for hand use only. Any clamping,
fix uring, or use of handle ex ensions voids his warran y.
CAUTION: Molex crimp specifica ions are valid only when used wi h Molex erminals and ooling.
CAUTIONS:
1. Manually powered hand ools are in ended for low volume or field repair. This ool is NOT in ended for
produc ion use. Repe i ive use of his ool should be avoided.
2. Insula ed rubber handles are no pro ec ion agains elec rical shock.
3. Wear eye pro ec ion a all imes.
4. Use only he Molex erminals specified for crimping wi h his ool.
Certification
Molex does no cer ify or re-cer ify hand ools bu ra her supplies he following guidelines for cus omers o re-cer ify
hand ools.
% This ool is qualified o pull force only. To re-cer ify, crimp a erminal o a wire, which has been s ripped
12.7mm (1/2”) long, so here is no crimping of he insula ion. Pull he erminal and wire a a ra e no fas er han
25mm (1.00”) per minu e. See he Molex web si e for he Quali y Crimp Handbook for more informa ion on pull
es ing.
% If he ool does no mee minimum pull force values, handle preload should be increased and he pull es
rerun, (See How o Adjus Preload).
% When he hand ool is no longer capable of achieving minimum pull force, i should be aken ou of service and
replaced.

Hand Crimp Tool for Commoning Crimp Terminals
Doc No: ATS-638250500 Release Da e: 02-14-11 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Da e: 02-14-11
RATCHET
RELEASE LEVER
2
Fi ure 13
1
3
PARTS LIST
Ite
m Number
Order Number
Description
Quantity
REF
63825
-
0500
Hand Crimp Tool
Figure 13
1
638
2
5
-
05
75
Loca or Assembly
1
2
63810
-
0104
Spring, Re urn
1
3
63810
-
0105
Spring, Ra che
1
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