molex 63825-5500 User guide

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Excellent Integrated System Limited
Excellent Integrated System Limited
Stocking Distributor
Stocking Distributor
Click to view price, real time Inventory, Delivery & Lifecycle Information:
Click to view price, real time Inventory, Delivery & Lifecycle Information:
Molex Connector Corporation
Molex Connector Corporation
0638255500
0638255500
For any questions, you can email us directly:
For any questions, you can email us directly:
[email protected]
[email protected]
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals
Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 1 of 7
Revision: A Revision Date: 09-05-12
CONDUCTOR
BRUSH
STRIP LENGTH
SEAM
CONDUCTOR
CRIMP HEIGHT
CUT
-
OFF
TAB
BELL MOUTH
BEND
UP
T
WISTING
ROLLING
BEND
DOWN
WIRE
INSULATION
CRIMP
HAND CRIMP
TOOL
Application Tooling
Sp cification Sh t Ord r No. 63825-5500
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
 This tool is RoH compliant, however RoH compliant is not required
SCOPE
Products: 1.80mm (.071") PC Board Crimp Terminal, 22-26 AWG.
T rminal S ri s No.
T rminal Ord r No.
Wir Siz and Typ
Insulation Diam t r
(Maximum) Strip L ngth



R l
AWG
mm²
mm
In.
mm
In.
35740
35740
-
8610
22
-
26
0.35
-
0.12
1.80
.
071
2.90
-
3.40
.114
-
.134

Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut
-
off Tab.
DEFINITION OF TERMS
TYPE 4D
2 / 8
2 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals
Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 2 of 7
Revision: A Revision Date: 09-05-12
▲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 (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.
T rminal
S ri s No.
Wir Siz
Conductor Crimp
Insulation Crimp
Pull Forc
Minimum Profil
H ight (R f.)
Width (R f.)
H ight (R f.)
Width (R f.)
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
22
24
26
35740
22
0.35
1.10
-
1.20
.043
-
.047
1
.45
.
057
2.05
.081
2.1
0
.083
39.2
8.7
X
24
0.20
1.00
-
1.10
.039
-
.043
1.45
.
057
1.85
.073
2.1
0
.083
29.4
6.5
X
26
0.
12
0.90
-
1.00
.035
-
.039
1.45
.
057
1.80
.071
2.10
.083
19.6
4.4
X
Tool Qualification Not s:
1. Pull Force should be measured with no
influence from the insulation crimp.
2. The above specifications are guidelines to
an optimum crimp
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 vary 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.
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.
MAKE SURE
CENTER OF
LOCATOR
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figur 2
SQUEEZE HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figur 1
3 / 8
3 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals
Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 3 of 7
Revision: A Revision Date: 09-05-12
RELEASE
LOCATOR
BUTTON
TERMINAL
Figur 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
Figur 5
TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE
-
STRIPPED WIRE
TERMINAL
Crimping T rminals
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
Figur 4
FIRST RATCHET
POSITION
OPEN
POSITION
4 / 8
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Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals
Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 4 of 7
Revision: A Revision Date: 09-05-12
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. ee Figure 6.
Locator R plac m nt
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.
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.
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
5 / 8
5 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals
Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 5 of 7
Revision: A Revision Date: 09-05-12
MATCH
UP MARKS
FRONT
BACK
Figur 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.
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 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 Pr load (S Figur 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.
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figur 10
RATCHET RELEASE
LEVER
Figur 11
6 / 8
6 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals
Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 6 of 7
Revision: A Revision Date: 09-05-12
Figur 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.
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
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.
7 / 8
7 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited
Datasheet of 0638255500 - HAND CRIMP TOOL
Contact us: [email protected] Website: www.integrated-circuit.com
Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals
Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 7 of 7
Revision: A Revision Date: 09-05-12
2
Figur 13
1
3
PARTS LIST
It m Numb r
Or
d r Numb r
D scription
Quantity
REF
638
2
5
-
55
00
Hand Crimp Tool
Figure 13
1
638
2
5
-
55
75
Locator Assembly
1
2
63810
-
0104
pring, Return
1
3
63810
-
0105
pring, Ratchet
1
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