molex 63825-1900 User manual

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 1 of 8
Revision A Revision Date 01-24-12
CONDUCTOR
BRUSH
STRIP LENGTH
WIRE SEAL
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAM
Application Tooling
Sp cification Sh t
Tool Kit
Ord r No. 63825-1970
Hand Crimp Tool
Ord r No. 63825-1900
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 2.80mm (.110") Sealed Crimp Terminal, Male and Female, 0.50-1.00mm² wire.
T rminal
S ri s No.
T rminal Ord r No. Wir Siz Insulation Diam t r Strip L ngth
(1) Availabl in R l
form only AWG
mm² mm in mm in
98012 98012-1102
- 0.50
1.40-2.30 .055-.091 4.7-5.7 .185-.224
- 0.75
- 1.00
98014 98014-0100
- 0.50
- 0.75
- 1.00
(1) Customer to cut off terminal from reel 0.35mm (.014”) maximum Cut-off Tab.
DEFINITION OF TERMS
TYPE 4C

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 2 of 8
Revision A Revision Date 01-24-12
ANVILS
POWER
CRIMP
HEAD
Figur 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
CRIMP SPECIFICATION
T rminal S ri s No. B ll Mouth B nd up B nd down Twist Roll Conductor Brush
mm In. D gr D gr mm In.
98012 0.35-0.70 .014-.028 3 3 4 8 0.20-1.00 .008-.039
98014 0.35-0.70 .014-.028 3 3 4 8 0.20-1.00 .008-.039
S am
Seam shall not be open and no wire allowed out of the crimping area
CONDITIONS:
After crimping, the conductor profiles should measure the following (See notes below).
T rminal S ri s No.
Wir Siz Conductor Pull Forc
Minimum Profil
Crimp H ight Crimp Width
AWG mm2 mm in. mm in. N Lb. A B C
98012
- 0.50 1.25-1.35 .049-.053 2.05-2.25 .081-.089 75 16.9 X
- 0.75 1.35-1.45 .053-.057 2.05-2.25 .081-.089 90 20.2 X
- 1.00 1.40-1.50 .055-.059 2.09-2.29 .082-.090 120 27.0 X
98014
- 0.50 1.25-1.35 .049-.053 2.05-2.25 .081-.089 75 16.9 X
- 0.75 1.35-1.45 .053-.057 2.05-2.25 .081-.089 90 20.2 X
- 1.00 1.40-1.50 .055-.059 2.09-2.29 .082-.090 120 27.0 X
T rminal
S ri s No.
Singl Wir S al S al Crimp
Crimp H ight Crimp Width
Ord r No. Color mm In. mm In.
98012 ♦024624A Green 3.90-4.10 .154-.161 3.90-4.10 .154-.161
98014
♦This wire seal is a Ford product and not a Molex product. Contact Ford for information on ordering this part.
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.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow
the steps below
Anvils and Punch s 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.

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 3 of 8
Revision A Revision Date 01-24-12
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figur 2
Locator Installation and R moval
Follow the steps below to install or replace the locator. See Figure 2.
To install th locator
1. Position the locator with the hole over the brass pivot shaft and snap it
into place.
To r mov th 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 T rminals
1. Select the desired 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 Figure 4.
5. Insert the proper 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.
6. Return the locator to its
original position.
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
LOCATOR TERMINAL IN PLACE
Figur 4
Figur 3
LATCH LOCKED
LATCH UNLOCKED

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 4 of 8
Revision A Revision Date 01-24-12
TERMINAL
PRE-STRIPPED
WIRE WITH SEAL
Figur 6
WIRE STOP
BLADE
HANDLE
OPEN
LOCATOR
CLOSED
Figur 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
7. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.
8. Insert the proper wire with the seal over the terminal.
9. Gently touch the wire stop with the end of the wire. See Figure 6 and 7.
10. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
11. 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.
12. Visually inspect the crimped terminal for proper crimp location.
Not The tamper proof ratchet action will not release the tool until it has been fully closed.
For th Batt ry Pow r 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.
Maint nanc
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. 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.
Figur 7
WIRE
INSULATION
PUNCH
CONDUCTOR
ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL
WIRE
SEAL

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 5 of 8
Revision A Revision Date 01-24-12
Figur 9
RETRACTOR
SLIDE
Miscrimps or Jams (Crimp Hand Tools Only)
(S Figur 12)
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 12.
Miscrimps or Jams (Batt ry Pow r d Tools)
(S Figur 9)
Should this tool ever become stuck or jammed in a partially closed position, Do Not force the power head
open or closed. The ram can be retracted before the crimping cycle is complete. To do this push the
retractor slide towards the battery. See Figure 9.
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.
C rtification
Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools.
Figur 8B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figur 8A

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 6 of 8
Revision A Revision Date 01-24-12
% 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.
% 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
Ord r No.
Tool
Ord r no.
Tool
D scription
Pow r H ad
Ord r No.
Adapt r
D scription
Figur
No.
63825-1970
63810-1050 Hand Crimp Frame (Short) N/A N/A 10
63810-1000 Hand Crimp Frame (Long) N/A N/A 10
63816-0200 Battery Power Tool (110 V) 63816-0300 Power Crimp Head 11
63816-0250 Battery Power Tool (220 V) 63816-0300 Power Crimp Head 11
Applications for th Tool Kit
Hand Crimp Tool Batt ry Pow r d Tool
Figur 10 Figur 11
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

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 7 of 8
Revision A Revision Date 01-24-12
RATCHET
RELEASE SCREW
Figur 12
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
It m Numb r Ord r Numb r D scription Quantity
1 63810-1000 Hand Crimp Frame (Long) 1
2 63825-1970 Tool Kit with Locator 1
3 63825-1975 Locator (only) REF

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female
Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 8 of 8
Revision A Revision Date 01-24-12
Figur 13
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
It m Ord r No Engin ring No. D scription Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63825-1970 63825-1970 Tool Kit with Locator 1
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