molex 63825-6070 User manual

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 1 of 8
Revision: A Revision Date: 4-26-13
INSULATION CRIMP
▲SEE NOTE
BRUSH
STRIP LENGTH
BEL
L MOUTH
CUT
-
OFF
TAB
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP HEIGHT
TWISTING
SEAM
WIRE
Application Toolin
Specification Sheet
Tool Kit
Order No. 63825-6070
Hand Crimp Tool
Order No. 63825-6000
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- 3 Power Crimp Head which is installed
into the 63816- 2 (11 V) or the 63816- 25 (22 V) Battery Powered Tool.
 Many different Tool kits can be used with a single Battery Powered Tool.
 This tool is IPC/WHMA-A-62 Class 2 and RoHS compliant.
SCOPE
Products: CSP 6.3 Receptacle Terminal, 3mm², 2mm² (double), and 5mm² metric wire.
Terminal Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Len th

Reel Form Only
Wire Style
mm²
mm
In.
mm
In.
98891 98891-1 13 T3 ZHID
3
3.
–
3.2
.118
–
.126
5. – 5.5 .2 – .22
2
x
2
2.
3
–
2.5
. 9
–
. 98
5 3.7 – 3.9 .146 – .154

Customer to cut off terminal from reel: .
3
mm (.
12
”) maximum Cut
-
off Tab.
DEFINITION OF TERMS
TYPE 4C

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 2 of 8
Revision: A Revision Date: 4-26-13
▲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 for the 3mm² and 5mm²
wires. This produces an overlap insulation
crimp (A62 – compliant). While the
insulation punch profile may appear
“lopsided”, this is a normal condition for this
tool. See figure to the right.
The 2 x 2mm² insulation crimp punch uses
the standard “B” crimp.
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
i
n.
mm
i
n.
De ree
s
(Max)
De ree
s
(Max)
9889
1
.4
–
.6
. 16
–
. 24
.2
–
1.8
. 8
–
. 7
3
3
3
1
Terminal Series No.
Wire Size
Con
ductor Crimp
Profile
Hei ht
Width
m
m
2
mm
i
n.
mm
i
n.
A
B
C
98891
3
1.87
–
1.93
. 74
–
. 76
3.6 – 3.7 .142 – .146
X
2
by
2
2. 7
–
2.13
. 81
–
. 84
X
5
2.27
–
2.33
. 89
–
. 92
X
Terminal Series No.
Wire Size
Insulation Crimp
Pull Force
Minimum
Hei ht
Maximum
Width
Maximum
mm
2
mm
i
n.
mm
i
n.
N
Lb.
98891
3
4.
.157
4.
7
.185
24
54
2 x 2
4.
.157
5.
4
.212
18
4
5
4.1
.161
5.2
.2 5
29
65
Tool Qualification Notes:
1. Pull force should be measured with no influence from the insulation crimp.
2. Pull force on the 2 x 2mm² crimp is based on pulling one wire.
3. 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 Molex 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

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 3 of 8
Revision: A Revision Date: 4-26-13
ANVILS
POWER
CRIMP
HEAD
Fi ure
1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Fi ure
2
Fi ure 4
SWING OPEN
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
LOCATOR
TERMINAL
IN PLACE
LOCATOR LATCH
IN OPEN POSITION
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 M4 x 1 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 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.

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 4 of 8
Revision: A Revision Date: 4-26-13
Fi ure 6
WIRE IN TERMINAL
JAWS
PARTIALLY
CLOSED
WIRE AGAINST
WIRE STOP
HANDLE
OPEN
LOCATOR
CLOSED
Fi ure 5
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
Crimpin Terminals
1. Select the desired terminal listed in the preceding charts.
2. Turn the Locator Lock Latch down to unlock. See Figure 3.
3. Swing the terminal locator away from the crimp tool shown in Figure 4. Some terminals with large insulation
grips may interfere with the crimp tooling when swinging the locator into position. The terminal must then be
loaded into the locator in the closed/crimp
position. See Figure 5.
4. Press down on the wire stop on the locator as
shown in Figure1. Insert the proper terminal
into the proper nest opening. Make 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. Make
sure that the terminal is visually centered over
the punch.
7. Insert the proper wire over the terminal.
8. Gently touch the wire stop with the end of the
wire. See Figure 6 and 7.
9. Compress the terminal by squeezing the tool
handles until the ratchet mechanism cycle has
been completed. Release handles to open the
jaws.
1 . 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.
Fi ure 7
WIRE
INSULATION
PUNCH
CONDUCTOR ANVIL
LOCATOR
INSULATION
ANVIL
WIRES AGAINST
LOCATOR STOP
CONDUCTOR
PUNCH
TERMINAL

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 5 of 8
Revision: A Revision Date: 4-26-13
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 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 3 weight automotive oil, every 5, crimps or monthly, will significantly enhance the tool life
and ensure a stable calibration. See Figure 8A or 8B for lubrication points.
4. Store the tool in a clean and dry area when not in use.
Miscrimps or Jams for Crimp Hand Tools Only (See Fi ure 11)
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 11.
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 3
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: 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.
CAUTION: Repetitive use of this tool should be avoided.
Certification
Molex 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)
Fi ure8A
Fi ure 8B

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 6 of 8
Revision: A Revision Date: 4-26-13
% 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. ”) per minute. See the Molex 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.
Ada
pter
Description Fi ure No.
63825-6 7
6381
-
1 5
Hand Crimp Frame (Short)
N/A
N/A
9
6381
-
1
Hand Crimp Frame (Long)
N/A
N/A
9
63816
-
2
Battery Power
Tool (11 V)
63816
-
3
Power Crimp Head
1
63816
-
25
Battery Power
Tool (22 V)
63816
-
3
P
ower Crimp Head
1
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Fi ure
9
Fi ure
10
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 Manual or
Specification Sheet. See Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make 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

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 7 of 8
Revision: A Revision Date: 4-26-13
RATCHET
RELEASE SCREW
Fi ure 11
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
6381
-
1
Hand Crimp Frame (Long)
1
2
6382
5
-
6
7
Tool Kit with
Locator
1
3
638
23
-
5
7
3
Locator Base
1
4
6382
5
-
6
75
Locator (only)
R
EF

Hand Crimp Tool for CSP 6.3 Receptacle Terminal
Doc No: ATS-638256 HM Release Date: 4-26-13 UNCONTROLLED COPY Page 8 of 8
Revision: A Revision Date: 4-26-13
Fi ure 12
1
2
2
M
4
by
8
Lon
BHCS
M
4
by
18
Lon
BHCS
M
4
by
10
Lon
BHCS
1
POWER HEAD PARTS LIST
Item
O
rder No
En ineerin No.
Description
Quantity
1
63816- 3 63816- 3 Power Crimp Head 1
2
63825-6 7 63825-577 Tool Kit 1
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