molex 63825-3000 User manual

Hand Crimp Tool For IllumiMate™ Crimp Terminal
Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 0 -07-12
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRI
MP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Hand Crimp
Tool
Application Toolin
Specification Sheet Order No. 63825-3000
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-620 Class 2 compliant as indicated
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: 1. 0mm (.0 9”) Wire-to-Board IllumiMate™ Receptacle Terminal, 28 AWG.
Terminal
Series No.
Terminal Order No.
Reel Form only
Wire Size
Insulation Diameter
Strip Len th
IPC/WHMA-A620 (1)
Terminal (2)
Insulation Maximum
AWG mm² mm In. mm In. mm In.
104 01 104 01-8003 28 0.08 0.8 -0.9 .033-.037 0.9 .037 1.00-1.30 .039-.0 1
Note: This terminal will accommodate UL Style 10368 wire.
(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.
(2) Overall insulation OD specification for terminal.
 Customer to cut off terminal from reel: 0.10mm (.004”) maximum Cut-off Tab.
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 IllumiMate™ Crimp Terminal
Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 0 -07-12
RELEASE
LOCATOR BUTTON
TERMINAL Fi ure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal Series No.
Wire Size Conductor Crimp Insulation Crimp Pull Force
Minimum
Hei ht Width (Ref.) Hei ht (Ref.) Width (Ref.)
AWG mm2 mm In. mm In. mm In. mm In. N Lb.
104 01 28 0.08 0.44-0.48 .017-.019 0.79 .031 1.20 .047 0.93 .037 9.8 2.2
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage can
occur to the tool or die.


 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 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.
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.
Crimpin 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.
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Fi ure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Fi ure 1

Hand Crimp Tool For IllumiMate™ Crimp Terminal
Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 0 -07-12
PRE-STRIPPED
WIRE
TERMINAL
Fi ure 5
TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE
WIRE STOP
IS PART OF
THE LOCATOR
PARTIALLY
CLOSE HANDLE
TOOLING PARTIALLY
CLOSED
Fi ure 4
FIRST RATCHET
POSITION
OPEN
POSITION
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.
. 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 .
7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism
cycle has been completed.
8. Release the handles to open the jaws.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
9. Remove the crimped terminal from the terminal
locator by pulling on the wire.
10. Visually inspect the crimped terminal for proper
crimp location.
11. 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 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.
1. Open the crimp hand tool.
2. 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.
TERMINAL
Fi ure 6
WIRE
WIRE STOP

Hand Crimp Tool For IllumiMate™ Crimp Terminal
Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 0 -07-12
Fi ure 8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT BACK
Fi ure 9
4. To reinstall the new locator, make sure the hand tool is in the open position.
. 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 (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 secure the locator into place, the
lower tabs must snap into place on the hand
tool frame.
Ri ht or Left Hand Operation
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.
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.
. Reinstall the locator by following the Instructions in the locator replacement section.
Maintenance
It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance
steps:
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Fi ure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Fi ure 7B

Hand Crimp Tool For IllumiMate™ Crimp Terminal
Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page of 7
Revision: A Revision Date: 0 -07-12
Fi ure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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 ,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.
. 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 Fi ure 12)
This hand tool is factory preset to 2 -4 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 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.
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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Fi ure 10
RATCHET RELEASE
LEVER
Fi ure 11

Hand Crimp Tool For IllumiMate™ Crimp Terminal
Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 0 -07-12
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
2 mm (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 IllumiMate™ Crimp Terminal
Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 0 -07-12
RATCHET
RELEASE LEVER
2
Fi ure 13
1
3
PARTS LIST
Item Number Order Number Description Quantity
REF 6382 -3000 Hand Crimp Tool Figure 13
1 6382 -307 Locator Assembly 1
2 63810-0104 Spring, Return 1
3 63810-010 Spring, Ratchet 1
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