molex 63825-5000 User manual

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal
Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 04-11-13
▲INSULATION CRIMP HEIGHT
BRUSH
STRIP LENGTH
BELL MOUTH
CONDUCTOR CRIMP HEIGHT
BEND DOWN
BEND UP
ROLLING
TWISTING
SEAM
CUT
-
OFF TAB
HAND CRIMP
TOOL
Application Toolin
Specification Sheet Order No. 63825-5000
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 RoH compliant, however RoH compliant is not required
SCOPE
Products: 2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal, 22-24 AWG.
Terminal Series No.
Terminal Order No.
Wire Size

Insulation Diameter
S
trip Len th
Loose Piece

Reel
AWG
mm²
mm
In.
mm
In.
503371 ---- 503371-0000 22-24 .178-0.34 1.15-1.70 .045-.067 2.40-2.80 .094-.110

Customer to cut off terminal from reel: 0.
20
mm (.00
8
”) maximum Cut
-
off Tab.
See Conditions on pa e 2.
DEFINITION OF TERMS
TYPE 4D

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal
Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 04-11-13
▲Insulation 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. ee figure to the right.
( ome tools with multiple crimp pockets may not have
the “overlap” profile on all pockets).
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal Series No Wire Size
Conductor Crimp


Profile
Hei ht
Width (Ref.)
503371
AWG
mm
2
mm
In.
mm
In.
22
24
22
0.3
1
-
0.34
.
880
-
.930
.035
-
.037
1.
30
-
1.32
.051
-
.052
X
24
0.178
-
0.2
2
.820
-
.870
.032
-
.034
1.
30
-
1.32
.051
-
.052
X

To Achieve IPC
-
A
-
620 Class 2 Crimps, the following over
-
all wire insulation diameter ranges are recommended:
Profile 22: 1.40 – 1.65mm (.055-.065 inch)
Profile 24: 1.30 – 1.60mm (.051-.063 inch)
Terminal Series No Wire Size
Insulatio
n Crimp
Pull Force Minimum
Hei ht (Ref.)
Width (Ref.)
503371
AWG
mm
2
mm
In.
mm
In.
N
Lb.
22
0.31
-
0.34
2.20
.087
1.70
-
1.90
.067
-
.075
34.3
7.71
24
0.178
-
0.22
2.07
.081
1.70
-
1.90
.067
-
.075
24.5
5.51
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
CAUTION: Install only Molex terminals
listed above with this tool. Do not crimp
hardened objects as damage can occur to
the tool or die.
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Fi ure 1
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Fi ure 2
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal
Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 04-11-13
RELEASE
LOCATOR BUTTON
TERMINAL Fi ure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
TERMINAL
WIRE AGAINST
THE WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
Fi ure 5
PRE
-
STRIPPED
WIRE
TERMINAL
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. ee Figure 1.
Crimpin Terminals
1. elect 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. ee Figure 2.
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. ee 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. ee Figure
4.
6. Insert the properly stripped wire through the terminal and against the wire
stop. ee 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
Fi ure 4
FIRST RATCHET
POSITION
OPEN
POSITION

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal
Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 04-11-13
Fi ure 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. ee Figure 6.
Locator Replacement
ee 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. queeze 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. ee 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 (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.
TERMINAL
Fi ure 6
WIRE
WIRE STOP
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Fi ure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Fi ure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal
Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 04-11-13
MATCH
UP MARKS
FRONT
BACK
Fi ure 9
2. Remove the M3 BHC which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side and replace
the M3 BHC . 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. ee 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.
Maintenance
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
hould 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. ee Figure
11.
How to Adjust Tool Preload (See Fi ure 12)
This hand tool is factory preset to 25-45 LB . 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.
LUBRIC
ATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Fi ure 10
RATCHET RELEASE
LEVER
Fi ure 11

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal
Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 04-11-13
Fi ure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
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.
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. hould 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
25mm (1.00”) per minute. ee 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, ( ee 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.

2.50mm Pitch Floating Wire-to-Board Plug Crimp Terminal
Doc No: AT -638255000 Release Date: 04-11-13 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 04-11-13
RATCHET
RELEASE LEVER
2
Fi ure 13
1
3
PARTS LIST
I
tem Number
Order Number
Description
Quantity
REF
63825
-
50
00
Hand Crimp Tool
Figure 13
1
63825
-
50
75
Locator Assembly
1
2
63810
-
0104
pring, Return
1
3
63810
-
0105
pring, Ratchet
1
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