molex 63825-2600 User manual

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 03-21-12
TYPE 4D
CONDUCTOR
BRUSH
STRIP LENGTH
CONDUCTOR
CRIMP
CUT-OFF
TAB
BELL
MOUTH
BEND UP
TWISTING
ROLLING
BEND
DOWN
WIRE
SEAM
INSULATION CRIMP
▲SEE NOTE
HAND CRIMP
TOOL
Applicatio Tooli g
Specificatio Sheet Order No. 63825-2600
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 or left handed operation
 IPC/WHMA A-620 Class 2 compliant as indicated
 RoHS compliant, however RoHS compliant is not required
 For 12AWG crimps use hand tool 63825-2700
SCOPE
Products: 3.18mm (.125”) Lighting Terminal for 16AWG and 18AWG wires.
Termi al
Series No.
Termi al Order No.
Reel Form o ly
Co ductor Size I sulatio Outside Diameter (1) Strip Le gth
AWG mm² mm I . mm I .
42824 42824-4001 16 - 18 1.3 – 0.8 1.90 – 3.10 0.075 – 0.122
3.8 – 4.3 0.15 – 0.17
42824-4004
42825 42825-4001 16 - 18 1.3 – 0.8 1.90 – 3.10 0.075 – 0.122
42825-4004
(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
 Customer to cut off terminal from reel: 0.40mm (.016”) maximum cut-off tab.
DEFINITION OF TERMS

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 03-21-12
▲I sulatio 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.
CRIMP SPECIFICATIONS
After crimping, the crimped terminals should
measure as follows:
Termi al Series No. Bell mouth Co ductor Brush
mm I . mm I .
42824 and 42825 0.20 - 0.60 0.008 - 0.024 1.00 -1.50 0.039 - 0.059
Termi al Series No.
Be d up
Be d dow Twist Roll Seam
Seam shall not be open and no wire
Allowed out of the crimping area
Degrees Degrees
42824 and 42825 3 3 4 8
Termi al
Series No.
Wire Size Co ductor Crimp I sulatio Crimp Pull Force
Mi imum
Height Width (Ref) Height Maximum Width Maximum
AWG mm2 mm I . mm I . mm I . mm I . N Lb.
42824 and 42825 18 0.8 1.52 – 1.60 0.060 – 0.063 2.30 0.090 3.9 0.15 4.0 0.16 116 26
42824 and 42825 16 1.3 1.58 – 1.66 0.062 – 0.065 2.30 0.090 4.2 0.17 4.2 0.17 178 40
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.


 Tool Qualificatio 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 durometer 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 specification.
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.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
SQUEEZE HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 03-21-12
PRE-STRIPPED WIRE
TERMINAL
Figure 5 TERMINAL
WIRE AGAINST
THE WIRE
STOP
WIRE
WIRE STOP IS
PART OF
THE LOCATOR
Crimpi g Termi als
1. Select the desired terminal listed in the preceding charts.
2. Make sure the locator is attached behind the lower tooling and is above all the
anvils surfaces.
3. The spring loaded wire stop should be clear of the locator’s cavity, if not push up
on the red tab to move the wire stop out of the way while inserting the terminal.
See Figure 3.
4. 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.
5. Partially close the tool handle until the first ratchet position engages, and
holds the terminal in place. 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.
ote: 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.
LOCATOR
IN DOWN
POSTION
RED
TAB
Figure 2
TERMINAL
Figure 3 TERMINAL
PUSH UP
ON THE
RED TAB
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figure 4
FIRST
RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 03-21-12
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
Figure 9
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
Locator Replaceme t
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.
2. Squeeze gently on the lower area shown in Figure 7 with
your thumb and index finger. The lower tabs of the
locator should 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 7.
4. To reinstall the new locator, make sure the hand tool is in the open
position.
5. 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.
6. Rotate the locator down and press the lower tabs into the two bottom
slots of the hand tool. To secure the locator into place, the lower
tabs must snap into place on the hand tool frame.
Right or Left Ha d Operatio
This hand tool has an added feature that can be converted from a right
handed application to a left 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.
TERMINAL
Figure 6
WIRE
STOP
WIRE
MATCH
UP MARKS
FRONT BACK
Figure 9

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 03-21-12
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
2. Remove the M3 BHCS which is holding the upper tooling. 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.
3. Do the same thing with the lower tooling and tighten the M3 screws. Be
sure the small markings line up.
4. Reinstall the locator by following the Instructions in the locator
replacement section.
Mai te a ce
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.
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 pressing up on the
ratchet release lever in the movable
handle. See Figure 11.
How to Adjust Tool Preload
(See Figure 12)
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:
RATCHET RELEASE
LEVER
Figure 11
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 03-21-12
1. Hold the hand tool in the palm of your hand as shown in Figure 12. Using the index finger squeeze the link
towards the top of the hand tool frame. 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).
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.
Warra ty
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 OT 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.
Certificatio
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.

Hand Crimp Tool For 3.18mm (.125”) Lighting Terminals
Doc o: ATS-638252600 Release Date: 03-21-12 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 03-21-12
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number Order Number Descriptio Qua tity
REF 63825-2600 Hand Crimp Tool Figure 13
1 63825-2675 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-0105 Spring, Ratchet 1
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