molex 63825-8100 User manual

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals
Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page of 7
Revision: B Revision Date: - - 6
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
HAND CRIMP
TOOL
Application Tooling
Specification S eet Order No. 63825-8100
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
 Dies and Locator from this tool can be used in the Battery Powered Tool Order No.638 6-0200 ( 0 V) or
638 6-0250 (220 V), with the use of the 638 6-0800 Crimp Head
 Many different tool kits can be used with a single Battery Powered Crimp Tool
 This tool is IPC/WHMA A-620 Class 2 compliant
 This tool is RoHS compliant, however RoHS compliant is not required
SCOPE
Products: C-Grid III™ Female Crimp Terminals, 22-24 AWG
Terminal Series No.
Terminal Order No.
Wire Size

Insulation Diameter
Strip Lengt
Loose Piece

Reel
AWG
mm²
mm
In.
mm
In.
90 9
90 9-2 09
90 9-2 0
90 9-2
90 9-0 09
90 9-0 0
90 9-0
22-24 0.35-0.20 .02- .47 .040-.058 2.80-3.30 . 0-. 30

Customer to cut off terminal from reel: 0. 5mm (.006”) maximum Cut
-
off Tab.
See Conditions on page 2.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
TYPE 4D

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals
Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 2 of 7
Revision: B Revision Date: - - 6
RELEASE
LOCATOR BUTTON
TERMINAL Figure 3
LOCATOR
PUSHED THRU
TOOLING
TERMINAL
LOCATOR
BUTTON
PUSHED IN
LOCATOR
CONDITIONS:
After crimping, the conductor profiles should measure the following.
Terminal
Series No
Wire Size
Condu
ctor Crimp
Insulation Crimp
Pull Force
Minimum Profile
Heig t
Widt (Ref.)
Heig t (Ref.)
Widt (Ref.)
90 9
AWG
mm
2
mm
In.
mm
In.
mm
In.
mm
In.
N
Lb.
22
2
4
22
0.35
0.7
5
-
0.8
0
.0
30
-
.032
.
40
.0
55
.60
.063
.60
.063
39.2
8.82
X
24
0.20
0.
68
-
0.
73
.02
7
-
.0
29
.
40
.0
55
.
7
0
.06
7
.
7
0
.06
7
29.4
6.6
X

To Achieve IPC
-
A
-
620 Class 2 Crimps, the following over
-
all wire insulation diameter ranges are recommended:
Profile 22: . 5 – .30mm (.045-.05 inch) (UL 06 - .25mm Dia.)
Profile 24: .25 – .40mm (.049-.055 inch) (UL 007 – .40mm Dia.)
Tool Qualification Notes:
. 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 document 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 preformed to check hand tool crimp. Pull Force value Must exceed
the Minimum pull force specifications listed.
OPERATION
CAUTION: Crimp only the Molex terminals
listed in the scope for this tool. Do not
crimp hardened objects as damage can
occur to the tool frame and/or crimp dies.
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. See Figure .
Crimping Terminals
LOCATOR
IN DOWN
POSTION
PUSH ON THE
LOCATOR BUTTON
Figure 2
SQUEEZE
HANDLES
TOGETHER
HANDLE WILL
SPRING OPEN
Figure 1

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals
Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 3 of 7
Revision: B Revision Date: - - 6
Figure 5 TERMINAL
WIRE AGAINST THE
WIRE STOP
WIRE
WIRE STOP IS PART
OF THE LOCATOR
PRE
-
STRIPPED
WIRE
TERMINAL
. Select 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. See 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. See 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. See Figure
4.
6. Insert the properly stripped wire through the terminal and against the
wire stop. See 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.
8. Remove the crimped terminal from the terminal locator by
pulling on the wire.
9. Visually inspect the crimped terminal for proper crimp location.
0. 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. See Figure 6.
Locator Replacement
See the parts list on the last page of this document for the proper locator order number. Follow the steps below to
replace the locator.
PARTIALLY
CLOSE HANDLE
TOOLING
PARTIALLY
CLOSED
Figu
re 4
FIRST RATCHET
POSITION
OPEN
POSITION
TERMINAL
Figure 6
WIRE
WIRE
STOP

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals
Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 4 of 7
Revision: B Revision Date: - - 6
Figure
8
PUSH ON
HANDLE
JAWS OPEN
PULL OPEN
TOOLING
TOOLING
M3 BHCS
MATCH
UP MARKS
FRONT
BACK
Figure 9
. Open the crimp hand tool.
2. Squeeze 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. See 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.
Rig t 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:
. The locator must be removed before reversing
the tooling.
2. Remove the M3 BHCS which is holding the upper
tooling.
3. Flip the upper tooling to the opposite side and replace the M3 BHCS. 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. See 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.
MAKE SURE
CENTER OF LOCATOR
IS IN THE
DOWN POSITION
Figure 7B
SQUEEZE
HERE
SQUEEZE
HERE
LOCATOR
Figure 7A
TOP HOOKS
TOP SLOTS OF
HANDTOOL
LOWER TABS

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals
Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 5 of 7
Revision: B Revision Date: - - 6
Figure 12
SQUEEZE
THE LINK IN
THE HANDLE
HOLD THE HAND
TOOL IN POSITION
SETTING
WHEEL
RATCHET
RELEASE LEVER
Maintenance
It is recommended that each operator of the tool be made aware of, and
responsible for, the following maintenance steps:
. 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
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
pressing up on the ratchet release lever in the movable handle. See
Figure .
How to Adjust Tool Preload (See Figure 12)
This hand tool is factory preset to 25-45
LBS. 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:
. Hold the hand tool in the palm of your
hand as shown in Figure 0. Using
the index finger squeeze the link
towards the top of the hand tool frame.
This will release the preload
adjustment wheel.
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).
LUBRICATION POINTS
(BOTH SIDES) LIGHT OIL
(EVERY 3 MONTHS OR
5,000 CRIMPS)
Figure 10
RATCHET RELEASE
LEVER
Figure 11

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals
Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 6 of 7
Revision: B Revision Date: - - 6
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. 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: Molex crimp specifications are valid only when used with Molex terminals and tooling.
CAUTIONS:
. 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
2.7mm ( /2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm ( .00”) per minute. See 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, (See 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.

Hand Crimp Tool For C-Grid III™ Female Crimp Terminals
Doc No: ATS-638258 00 Release Date: -27- 2 UNCONTROLLED COPY Page 7 of 7
Revision: B Revision Date: - - 6
RATCHET
RELEASE LEVER
2
Figure 13
1
3
PARTS LIST
Item Number
Order Number
Description
Quantity
REF
63825
-
8100
Hand Crimp Tool
Figure 13
638
25
-
8
75
Locator Assembly
2
638 0
-
0 04
Spring, Return
3
638 0
-
0 05
Spring, Ratchet
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