molex 63825-6900 User guide

Hand Crimp Tool for Board-In Crimp Terminals
Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 1 of 6
Revision: A Revision Date: 07-25-12
INSULATION
CRIMP
▲SEE NOTE
BRUSH
STRIP
LENGTH
BELL MOUTH
COND.CRIMP
HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
CUT
-
OFF TAB
SEAM
Applicatio Tooli g
Specificatio Sheet
Modular Crimp Head
Order No. 63825-6970
Ha d Crimp Tool
Order No. 63825-6900
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
% odular Crimp Head is removable and can be use in the Air Powered Tool Order No.63816-0100,
accompanied by Air Powered Crimp Adapter (Order No. 63816-0700).
% Can also be used in the Battery Powered Tool Order No.63816-0200 (110 V) or 63813-0250 (220 V),
accompanied by Battery Powered Crimp Adapter (Order No. 63816-0600).
SCOPE
Products: 2.50mm Pitch Board-In Crimp Terminal, ale, 20-24 AWG.
Termi al
Series
Termi al Order No.
Wire Size

I sulatio Diameter
Wire Strip Le gth

Reel
Loose
AWG
mm²
mm
I .
mm
I .
50097
50097
-
8000
500
97
-
8100
20
-
24
0.50
-
0.20
1.40
-
1.90
.055
-
.075
2.50
-
3.00
.098
-
.118

Customer to cut off terminal from reel: 0.
01
mm (.0
04
”) maximum Cut
-
off Tab
.
 See crimp specification for the individual Insulation Diameter.
DEFINITION OF TERMS
This illustration is a generic terminal representation and not an exact image of any terminal listed in the scope.
TYPE 4A

Hand Crimp Tool for Board-In Crimp Terminals
Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 2 of 6
Revision: A Revision Date: 07-25-12
▲I sulatio 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).
CRIMP SPECIFICATIONS:
After crimping, the crimp profiles should measure the following.
Termi al Series No.
Wire Size
Co ductor Crimp
Profile
Height
Width
(Ref.)
AWG
mm²
mm
I .
mm
I .
A (24)
B (22)
C (20)
50097
20
0.50
0.92
-
1.02
.036
-
.040
1.30
-
1.40
.051
-
.055
X
22
0.35
0.84
-
0.89
.033
-
.035
1.30
-
1.40
.051
-
.055
X
24
0.20
0.77
-
0.82
.030
-
.032
1.30
-
1.40
.051
-
.055
X
Termi al Series No. Wire Size I sulatio Diameter 
I sulatio Crimp
Maximum
Pull Force
Mi imum
Height
(Ref.)
Width
(Ref.)
AWG
mm²
mm
I .
mm
I .
mm
I .
N
Lb.
50097
20
0.50
1.40
-
1.90
.055
-
.0
75
1.90
.075
1.90
.075
58.
8
13.21
22
0.35
1.40
-
1.90
.055
-
.075
1.90
.075
1.90
.075
39.
2
8.81
24
0.20
1.40
-
1.90
.055
-
.075
1.90
.075
1.90
.075
29.4
6.61

To Achieve IPC
-
A
-
620 Class 2 Crimps, the following over
-
all wire insulation diameter ranges are reco
mmended:
Profile A (24): 1.40-1.90mm (.055-.075 in.)
Profile B (22): 1.40-1.60mm (.055-.063 in.)
Profile C (20): 1.60-1.90mm (.063-.075 in.)
Tool Qualificatio Notes:
1. Pull Force should be measured with no influence from the
insulation crimp.
2. The above specifications are guidelines to an optimum
crimp.
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.
Crimpi g Termi als
1. With the hand tool in the open position, pivot the terminal
locator open by pulling up on the locator knob and lift the
wire stop blade up. See Figure 1.
2. Insert the terminal into the correct profile until the terminal is fully seated and stops. ake sure the wire
stop blade is fully seated on the terminal behind the conductor grip section.
OVERLAP
INSULATION
CRIMP
OVERLAP FORM GEOMET
RY
ANVIL
PUNCH
WIRE
TERMINAL
SEATED IN
LOCATOR
LOCATOR
OPEN
Figure 1
HAND TOOL
OPEN

Hand Crimp Tool for Board-In Crimp Terminals
Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 3 of 6
Revision: A Revision Date: 07-25-12
WIRE
CONDUCTOR
PUNCH
TERMINAL
WIRE STOP
BLADE
Figure 2
WIRE
CONDUCTOR
PUNCH
WIRE STOP
BLADE
INSULATION
PUNCH
LOCATOR
CONDUCTOR
ANVIL
INSULATION
ANVIL
TERMINAL
Figure 3
3. Gently pivot the locator closed.
4. Bring down the wire stop blade.
5. Slide the pre-stripped wire into the terminal; make sure to aim the
wire brush towards the tip point on the wire stop blade. See Figure
2. Align the wire so that it is parallel and sitting into the terminal.
aintain a light and constant pressure on the wire that is seated in
the terminal at all times. (Do not let go of the wire.) Be sure to
hold the wire and terminal in place until the terminal is fully
crimped. See Figure 3.
6. Close the tool until the ratchet releases.
7. Lift the wire stop blade up.
8. Carefully remove the crimped terminal.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
Note: To maintain good brush control and a consistent bell mouth the crimping instructions must be followed.
Termi al Locator Replaceme t/Cha ge Over
This section describes the procedure for changing locators.
Removal
1. With the tool in the open position, pivot the terminal locator outward.
2. Remove the 4 BHCS. See Figure 4.
I stallatio
1. Place the proper locator, on the hand tool. Install the 4 BHCS. See
Figure 4.
2. Tighten the screw enough to hold the locator. ake sure the locator can still float freely with hand pressure.
3. Insert the proper terminal fully into the correct profile slot until the terminal is fully seated and stops. Then
gently pivot the locator closed.
4. With hand pressure, slowly slide the locator to the correct
position. See Figure 5.
5. Gently pivot the locator open without disturbing the location.
6. Hold the locator firmly in place and slowly tighten the 4 BHCS.
Mai te a ce
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.
M4 BHCS
PIVOT LOCATOR
Figure 4

Hand Crimp Tool for Board-In Crimp Terminals
Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 4 of 6
Revision: A Revision Date: 07-25-12
INCORRECT
Figure 5
CORRECT
INCORRECT
3. ake 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
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 lifting the ratchet release lever. See Figure 6.
Warra ty
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: Repetitive use of this tool should be avoided.
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.
Notes:
1. This tool should only be used for the terminals and wire gauges specified on this sheet.
2. This tool is not adjustable for crimp height, however crimp force is adjustable (See instructions above).
Variations in tools, terminals, wire stranding and insulation types may affect crimp height.
3. This tool is intended for standard conductor sizes. It may not give a good insulation crimp support for all
insulation sizes.
4. olex does not repair hand tools (see warranty above). The replacement parts listed are the only parts
available for repair. If the handles or crimp tooling is damaged or worn, a new tool must be purchased.

Hand Crimp Tool for Board-In Crimp Terminals
Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 5 of 6
Revision: A Revision Date: 07-25-12
MODULAR
CRIMP
HEAD
BAT
TERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POWER
CRIMP
ADAPTER
5. Pull force should be used as the final criteria for an acceptable crimp. Pull force is measured with no
influence from the insulation crimp. The insulation should be stripped long (1/2 in.) so the insulation grips
on the terminal do not grip the wire insulation or the conductor. Refer to olex Quality Crimping
Handbook 63800-0029 for additional information on crimping and crimp testing.
6. olex does not certify crimp hand tools.
CAUTION: olex crimp specifications are valid only when used with olex terminals and tooling.
Applicatio s for the Modular Crimp Head
WARNING: NEVER operate, service, install, or adjust this odular Crimp Head without proper instruction
and without first reading and understanding the instructions in the proper anual or Specification Sheet.
See Chart below for the correct anual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Disconnect the
power by unplugging or turn off the Actuator from its power source.
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.
The chart below shows all applications for this odular Crimp Head.
Modular Crimp Head
Order No.
Tool
Order o.
Tool
Descriptio
Adapter
Order No.
Adapter
Descriptio Figure No.
63825-6970
63816
-
0000
Hand Crimp Frame (Short)
N/A
N/A
3
63816
-
0050
Hand Crimp Frame (Long)
N/A
N/A
3
63816
-
0200
Battery Power
Tool (110 V)
63816
-
0600
Battery Power Crimp Adapter
4
63816
-
0250
B
attery Power
Tool (220 V)
63816
-
0600
Battery Power Crimp Adapter
4
63816
-
0100
Air
Po
w
er
Tool
63816
-
0700
Air Power Crimp Adapter
5
Applicatio s for the Modular Crimp Head
Ha d Crimp Tool
Battery Powered Tool
Air Powered Tool
Figure
6
Figure
7
Figure
8
MODULAR
CRIMP
HEAD
LOCKING
PINS
HAND CRIMP
FRAME LONG
OR SHORT

Hand Crimp Tool for Board-In Crimp Terminals
Doc No: ATS-6382569H Release Date: 07-25-12 UNCONTROLLED COPY Page 6 of 6
Revision: A Revision Date: 07-25-12
RATCHET
RELEASE LEVER
HANDLE
SPRING
CRIMPING
SPRING (2)
LOCATOR
2
1
Figure 9
M4 X 6mm
LONG BHCS
3
4
6
5
PARTS LIST
Ha d Crimp Tool
63825
-
69
00
Item
Order Number
Descriptio
Qua tity
1
63825
-
69
70
odular
Crimp
Head
1 (
R
ef)
2
63816
-
00
5
0
Hand Crimp
Frame
(
Short
)
1
(
R
ef)
3
63825
-
69
75
Locator
1
4
63816
-
0001
Locking
Pin
2
5
63600
-
0525
Handle Spring
1
6
63600
-
0520
Crimping Spring
2
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