molex 63825-2800 User manual

Hand Crimp Tool For Quick Disconnect, Female Terminals
Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 09-1 -1
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
TERMINAL
STRIP
CONDUCTOR
CRIMP HEIGHT
CUT
-
OFF
TAB
SEAM
BELL MOUTH
WIRE
HAND CRIMP
TOOL
Application Tooling
Sp cification Sh t Ord r No. 63825-2800
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
 This tool is IPC/WHMA A-6 0 Class compliant as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: Quick Disconnect, Female, for 0.5, 0.8mm² & 1.0mm² and 18- 0 AWG wire,
T rminal S ri s No. T rminal Ord r No. Wir Siz
Insulation Diam t r
Maximum Strip L ngth
mm²
AWG
mm
In.
mm
In.
94030
94030
-
40 0
94030
-
40 1
0.50-1.00 18 - 0 .60 .10 4.5 - 5.5 .177 -. 17
94030
-
4530
94030
-
4531
●
Customer to cut off terminal from reel
. Cut tabs flush with terminal at both ends.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
TYPE 4D

Hand Crimp Tool For Quick Disconnect, Female Terminals
Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page of 7
Revision: A Revision Date: 09-1 -1
CONDITIONS:
After crimping, the conductor profiles should measure the following.
T rminal
S ri s No
Wir Siz
Conductor Crimp
▲
Insulation Crimp
Pull Forc
Minimum Profil
H ight Width Maximum
H ight (R f.)
Maximum
Width (R f.)
Maximum
AWG
mm
2
mm
In.
mm
In
.
mm
In.
mm
In.
N
Lb.
18
20
94030
0
0.5
1.30
–
1.40
.051
-
.055
.30
.091
3.10
.1
3.5
0
.1
38
78.4
17.6
X
18
0.
8
1.
4
0
–
1.
5
0
.05
5
-
.05
9
.
3
0
.091
3.1
5
.
1
4
3.5
0
.138
117.6
6.4
X
1.0
1.
45
–
1.
5
5
.05
7
-
.0
61
.
3
0
.091
3.
0
.1
6
3.5
0
.138
156.8
35.
X
Tool Qualification Notes:
1. Pull Force should be measured with no
influence from the insulation crimp.
. The above specifications are guidelines
to an optimum crimp.
▲Insulation Crimp Not :
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 (A6 0 – 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).
OPERATION
CAUTION: Install only Molex terminals listed
above with this tool. Do not crimp hardened
objects as damage can occur to the tool or die.
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.
Crimping T rminals
1. Select the desired terminal listed in the
preceding charts.
. 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 .
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figur 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figur 1
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Hand Crimp Tool For Quick Disconnect, Female Terminals
Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 09-1 -1
RELEASE
LOCATOR BUTTON
TERMINAL
Figur 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
PRE
-
STRIPPED WIRE
TERMINAL
WIRE AGAINST THE
WIRE STOP
Figur 5 TERMINAL
WIRE
WIRE STOP IS PART
OF THE LOCATOR
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.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figur 4
FIRST RATCHET
POSITION
OPEN
POSITION

Hand Crimp Tool For Quick Disconnect, Female Terminals
Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 09-1 -1
Figur
8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
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.
Not :
A crimp height chart is provided with this manual 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 R plac m nt
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.
. Squeeze gently on the lower area shown in Figure
7A 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 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.
6. Holding onto the lower part of the locator with your
thumb and index finger, insert the locators top
hooks ( ) 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
secure the locator into place, the lower tabs must
snap into place on the hand tool frame.
TERMINAL
Figur 6
WIRE
WIRE STOP
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figur 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figur 7B

Hand Crimp Tool For Quick Disconnect, Female Terminals
Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 09-1 -1
MATCH
UP MARKS
FRONT
BACK
Figur 9
Right or L ft Hand Op ration
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.
. 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.
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.
. 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 Pr load (S Figur 12)
This hand tool is factory preset to 5-45 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:
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figur 10
RATCHET RELEASE
LEVER
Figur 11

Hand Crimp Tool For Quick Disconnect, Female Terminals
Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 09-1 -1
Figur 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link
towards the top of the hand tool
frame. This will release the preload
adjustment wheel.
. 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.
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.
. 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.
C rtification
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
1 .7mm (1/ ”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
5mm (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 Quick Disconnect, Female Terminals
Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 09-1 -1
2
Figur 13
1
3
PARTS LIST
It m Numb r
Ord r Numb r
D scription
Quantity
REF
638
5
-
8
00
Hand Crimp Tool
Figure 13
1
638
5
-
8
75
Locator Assembly
1
63810
-
0104
Spring, Return
1
3
63810
-
0105
Spring, Ratchet
1
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