molex 63825-5800 User guide

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 08-13-12
INSULATION CRIMP
▲SEE NOTE
BR
USH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Application Tooling
Speci ication Sheet
Tool Kit
Order No. 63825-5870
Hand Crimp Tool
Order No. 63825-5800
FEATURES
% A full cycle ratcheting hand tool ensures complete crimps
% Ergonomically designed soft handles
% Precisely designed crimping profiles with simple contact positioning
% Easy handling due to outstanding force ratio
 Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
 any different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WH A-A-620 Class 2 and RoHS compliant.
SCOPE
Products: CSP 6.3 Receptacle Terminal, 0.35 mm² + 1.00mm², 0.75 mm² + 1.00mm², & (2) 1.00mm² metric wires.
Terminal
Series No.
Terminal
Order No. Wire Size Insulation Diameter Strip Length

Reel Form
Only Wire Style mm² mm In. mm In.
98891 98891-1012
IR
0.35+
1.00
1.25
-
1.40 +
1.99
-
2.15
.049
-
.055 +
.078
-
.085
5.50 .217
I
D
0.75+1.00
1.
6
0
-
1.
8
0 +
1.
75
-
1.90
.0
63
-
.0
70
+.0
68
-
.0
75
IR 1.00+1.00 (2) 1.99-2.15 (2) .078-.085

Customer to cut off terminal from reel: 0.
3
0mm (.
0
12
”) maximum Cut
-
off Tab.
DEFINITION OF TERMS
TYPE 4C

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 08-13-12
▲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. See figure to the right. (Some tools with
multiple crimp pockets may not have the
“overlap” profile on all pockets).
CONDITIONS:
After crimping, the conductor profiles should
measure the following (see notes below).
Terminal Series No.
Bell mouth
Conductor Brush
Bend up Bend Down
Twist Roll
mm
In.
mm
In.
Degree
(Max)
Degree
(Max)
9889
1
0.40
-
0.80
.
015
-
.030
0.20
-
1.
8
0
.008
-
.0
70
3
3
10
3
Terminal Series No.
Wire Size
Conductor
Crimp
Pro ile
Height
Width
m
m
2
mm
In.
mm
In.
A
B
C
98891
0.35+
1.00
1.
77
-
1.83
.0
70
-
.0
72
2.
78
-
2.84
.1
09
-
.112
X
0.75+1.00
1.92
-
1.98
.
.075
-
.077
2.78
-
2.84
.109
-
.112
X
1.00+1.00
2.02
-
2.08
.079
-
.081
2.78
-
2.84
.109
-
.112
X
Terminal Series No.
Wire Size
Insulation Crimp
Pull Force
Minimum
Height
Width Maximum
mm
2
mm
In.
mm
In.
N
Lb.
98891
0.35+1.00
2.55
-
2.75
.100
-
.108
4.41
-
4.61
.174
-
.181
50.0
11.23
0.75+1.00
2.60
-
2.80
.102
-
.110
4.41
-
4.61
.174
-
.181
90.0
20.22
1.00+1.00
3.15
-
3.35
.124
-
.13
2
4.41
-
4.61
.174
-
.181
120.0
26.96
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, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the
minimum pull force specifications listed.
CAUTION: Install only olex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMETRY
ANVIL
PUNCH
WIRE

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 08-13-12
ANVILS
POWER
CRIMP
HEAD
Figure
1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWI
NG
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure
2
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the 4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the 4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
To install the locator
1. Position the locator with the hole over the brass pivot shaft and snap it into place.
To remove the locator
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the
hand tool.
3. Firmly press down on the brass pivot shaft with your
thumb, while pulling the locator up. Slip the locator
off the top of the brass pivot shaft.
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.
Crimping Terminals
1. Select the desired terminal listed in the preceding charts.
2. Turn the Locator Lock Latch down to unlock. See Figure 3.
Figure 3
LATCH LOCKED
LATCH UNLOCKED

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 08-13-12
Figure 4
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP LOCATOR
TERMINAL
IN PLACE
Figure 5
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
3. Swing the terminal locator away from the crimp tool shown in Figure 4.
4. Press down on the wire stop on the locator and insert the proper terminal into the proper nest opening. ake
sure when choosing the nest opening, it will correspond with the A, B or C profile on the hand tool.
5. Return the locator to its original position.
6. Turn the Locator Lock Latch up to lock. ake sure that the terminal is visually centered over the punch.
7. Insert the proper wire over the terminal.
8. Gently touch the end of the wire against the wire stop in the locator. See Figures 5 & 6
9. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
10. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
11. Visually inspect the crimped terminal for proper crimp location.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal to the wire.
2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
3. Visually inspect the crimped terminal for proper crimp location.
Figure 6
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
WIRE STOP
CONDUCTOR
PUNCH
TERMINAL

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 08-13-12
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. ake certain all pins; pivot points and
bearing surfaces in the tool head are
protected with a thin coat of high quality
machine oil. Do not oil excessively. This tool was engineered for durability, but like any fine piece of
equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. The use of
light oil, such as 30 weight automotive oil, every 5,000 crimps or monthly, will significantly enhance the tool life
and ensure a stable calibration. See Figure 7A or 7B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams or Crimp Hand Tools Only (See Figure 10)
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 rotating the small slotted screw marked with an arrow. See Figure 10.
Warranty
This tool kit is for electrical terminal crimping purposes only. This tool kit 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 kit free of charge. This repair or exchange
will not be applicable to altered, misused, or damaged tools.
CAUTION: olex crimp specifications are valid only when used with olex terminals and tooling.
CAUTIONS
1. anually 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 olex terminals specified for crimping with this tool.
CAUTION: Repetitive use of this tool should be avoided.
Certi ication
olex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools.
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figu
re7A
Figure 7B

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 08-13-12
% 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 olex web site for the Quality Crimp Handbook for more information on pull
testing.
% When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.
% This tool is very difficult to disassemble and reassemble. Customer repair is not recommended.
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No. Tool Order No.
Tool Description
Power
Head
Order No.
Adapter
Description Figure No.
63825-5870
6381
0
-
1050
Hand Crimp Frame (Short)
N/A
N/A
8
6381
0
-
100
0
Hand Crimp Frame (Long)
N/A
N/A
8
63816
-
0200
Battery Power
Tool (
110 V)
63816
-
0300
Power Crimp Head
9
63816
-
0250
Battery Power
Tool (220 V)
63816
-
0300
Power Crimp Head
9
Applications or the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure
8
Figure
9
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper anual or
Specification Sheet. See Chart above for the correct anual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. ake sure the
power is turned off.
CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.
CAUTION: Wear safety glasses when operating or serving this tool.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING KIT

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 08-13-12
RATCHET
RELEASE SCREW
Figure 10
M4 X 8mm
LONG BHCS
2
1
3
M4 X 18mm
LONG BHCS
M4 X 10mm
LONG BHCS
2
4
WITH TOOL
KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810
-
1000
Hand Crimp Frame (Long)
1
2
6382
5
-
5
8
70
Tool Kit with
Locator
1
3
638
23
-
05
7
3
Locator Base
1
4
6382
5
-
5
8
75
Locator (only)
R
EF

Tool Kit for CSP 6.3 Receptacle Terminal
Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 08-13-12
Figure 11
1
2
2
M
4
by
8
Long
BHCS
M
4
by
18
Long
BHCS
M
4
by
10
Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63816-0300 63816-0300 Power Crimp Head 1
2
63825-5870 63825-5870 Tool Kit 1
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