molex 63825-9900 User manual

IDT Hand Tool
Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 1 o 6
Revision: A Revision Date: 05-24-13
RAST R5
IDT
Hand Tool
Application Tooling
Specification Sheet
Order No 6
3825
-
9
9
00
FEATURES
% Terminates wire directly into the direct and indirect R5 connectors
% Accommodates 2 to 11 circuit connectors
% A ull cycle ratchet ensures complete terminations
% This tool is designed or prototype or low volume work only and is not intended or production
SCOPE
Products: 5.0mm RAST R5 IDT Female Connectors, Direct and Indirect, Series 93055, 93065, 93244, and 93395.
Product List
The ollowing is a partial list o the product order numbers that this tool is designed to run. Updates to this list are
available on www.molex.com.
Connector
Series No
Connector Order No
93055
93055
-
0101
93055
-
0102
93055
-
0103
93055
-
0104
93055
-
0105
93055
-
0106
93055
-
0107
93055
-
0108
93055
-
0109
93055
-
0110
93055
-
0111
93055
-
0112
93055
-
0113
93055
-
0114
93055
-
0116
93055
-
0117
93055
-
0118
93055
-
0119
93055
-
0120
93055
-
0121
93055
-
0122
93055
-
0123
93055
-
0124
93055
-
0125
93055
-
0126
93055
-
0128
93055
-
0129
93055
-
0130
93055
-
0131
93055
-
0132
93055
-
0133
93055
-
0134
93055
-
0135
93055
-
0136
93055
-
0137
93055
-
0138
93055
-
0139
93055
-
0140
93055
-
0142
93055
-
0143
93055
-
0
146
93055
-
0144
93055
-
0145
93055
-
0147
93055
-
0148
93055
-
0149
93055
-
0150
93055
-
0151
93055
-
0152
93055
-
0153
93055
-
0154
93055
-
0155
93055
-
0159
93055
-
0160
93055
-
0161
93055
-
0162
93055
-
0163
93055
-
0164
93055
-
0201
93055
-
0202
93055
-
0203
93055
-
0204
93055
-
0205
93055
-
0206
93055
-
0207
93055
-
0208
93055
-
0209
93055
-
0210
93055
-
0211
93055
-
0212
93055
-
0213
93055
-
0214
93055
-
0215
93055
-
0216
93055
-
0217
93055
-
0218
93055
-
0219
93055
-
0220
93055
-
0221
93055
-
0222
93055
-
0223
93055
-
0224
93055
-
0225
93055
-
0226
93055
-
0227
93055
-
0228
930
55
-
0229
93055
-
0230
93055
-
0231
93055
-
0232
93055
-
0233
93055
-
0235
93055
-
0236
93055
-
0237
93055
-
0238
93055
-
0239
93055
-
0241
93055
-
0301
93055
-
0302
93055
-
0303
93055
-
0304
93055
-
0305
93055
-
0306
93055
-
0307
93055
-
0308
93055
-
0309
93055
-
0310
93055
-
0311
93055
-
0312
93055
-
0313
93055
-
0314
93055
-
0315
93055
-
0316
93055
-
0317
93055
-
0318
93055
-
0319
93055
-
0320
93055
-
0321
93055
-
0324
93055
-
0325
93055
-
0326
93055
-
0401
93055
-
0402
93055
-
0403
93055
-
0404
93055
-
0405
93055
-
0406
93055
-
0407
93055
-
0408
93055
-
0409
93055
-
0410
93055
-
04
11
93055
-
0412
93055
-
0413
93055
-
0414
93055
-
0415
93055
-
0416
93055
-
0417
93055
-
0418
93055
-
0419
93055
-
0420
93055
-
0421
93055
-
0422
93055
-
0423
93055
-
0501
93055
-
0502
93055
-
0503
93055
-
0504
93055
-
0505
93055
-
0506
93055
-
0507
93055
-
0508
93055
-
0509
93055
-
0510
93055
-
0511
93055
-
0601
93055
-
0602
93055
-
0603
93055
-
0604
93055
-
0605
93055
-
0606
93055
-
0607
93055
-
0608
93055
-
0609
93055
-
0610
93055
-
0611
93055
-
0612
93055
-
0613
93055
-
0614
93055
-
0615
93055
-
0616
93055
-
0617
93055
-
0618
93055
-
0701
93055
-
0702
93055
-
0703
93055
-
0704
93
055
-
0705
93055
-
0706
93055
-
0707
93055
-
0708
93055
-
0709
93055
-
0710
93055
-
0711
93055
-
0712
93055
-
0713
93055
-
0801
93055
-
0802
93055
-
0803
93055
-
0804
93055
-
0805
93055
-
0806
93055
-
0807
93055
-
0808
93055
-
0809
93055
-
0901
93055
-
0902
93055
-
0903
93055
-
0904
93055
-
0905
93055
-
0906
93055
-
0907
93055
-
0908
93055
-
0909
93055
-
0910
93055
-
0911
93055
-
0912
93055
-
0913

IDT Hand Tool
Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 2 o 6
Revision: A Revision Date: 05-24-13
93065
93065
-
1001
93065
-
1101
93065
-
1102
93065
-
2001
93065
-
2002
93065
-
2003
93065
-
2004
93065
-
2005
93065
-
2006
93065
-
2007
93065
-
3001
93065
-
3002
93065
-
3003
93065
-
3004
9306
5
-
3005
93065
-
3006
93065
-
3007
93065
-
3008
93065
-
3009
93065
-
3010
93065
-
4001
93065
-
4002
93065
-
5001
93065
-
5002
93065
-
5003
93065
-
5004
93065
-
6001
93065
-
6002
93065
-
7001
93065
-
7002
93065
-
7003
93065
-
8001
93065
-
8002
93065
-
8003
93065
-
8004
93065
-
8005
93065
-
8006
9
3065
-
8007
93065
-
9001
93065
-
9002
93065
-
9003
93065
-
9004
93065
-
9005
93065
-
9006
93244
93244
-
0101
93244
-
0103
93244
-
0104
93244
-
0106
93244
-
0107
93244
-
0108
93244
-
0109
93244
-
0110
93244
-
0111
93244
-
0112
93244
-
0113
93244
-
0114
93244
-
0115
93244
-
0116
93244
-
0117
93244
-
0118
93244
-
0119
93244
-
0120
93244
-
0121
93244
-
0122
93244
-
0123
93244
-
0124
93244
-
0125
93244
-
0127
93244
-
0128
93244
-
0130
93244
-
0131
93244
-
0136
93244
-
0137
93244
-
0138
93244
-
0139
93244
-
0201
93244
-
0202
93244
-
0204
93244
-
0205
93244
-
0206
93244
-
0207
93244
-
02
08
93244
-
0209
93244
-
0210
93244
-
0211
93244
-
0212
93244
-
0213
93244
-
0214
93244
-
0215
93244
-
0216
93244
-
0217
93244
-
0219
93244
-
0220
93244
-
0221
93244
-
0222
93244
-
0223
93244
-
0225
93244
-
0226
93244
-
0228
93244
-
0301
93244
-
0302
93244
-
0303
93244
-
0304
93244
-
0305
93244
-
0306
93244
-
0307
93244
-
0308
93244
-
0309
93244
-
0310
93244
-
0311
93244
-
0312
93244
-
0315
93395
93395
-
0101
93395
-
0102
93395
-
0105
93395
-
0126
93395
-
0133
93395
-
0134
93395
-
0135
93395
-
0136
93395
-
0201
93395
-
0202
93395
-
0203
93395
-
0218
93395
-
0227
93395
-
0228
9339
5
-
0229
93395
-
0230
93395
-
0231
93395
-
0232
93395
-
0233
93395
-
0301
93395
-
0313
Applicable Wires
Connector Series No
Conductor Size
Insulation Diameter Maximum
93055
93065
0.5mm²
2.10mm
0.75mm²
2.44mm
1.0mm²
2.55mm
93244
93395 1.5mm² 2.90mm
Tool Set-Up
The tool is adjusted or connector circuit size as ollows:
1. Slide the connector nest out o the tool rame.
2. Loosen the adjustable post by turning the knurled top
counterclockwise (CCW) one-hal turn.
3. Slide the adjustable post to the end o its slot, the arthest away rom
the stop block. See Figure 1.
4. Place the connector in the connector nest and slide it up against the
stop block as shown in Figure 2.
5. Move the adjustable post against the side o the connector and tighten it by turning the knurled top clockwise
(CW). See Figure 3. Do not use tools to tighten the adjustable post; inger-tight is su icient.
Figure 2
ADJUSTABLE POST
CONNECTOR
Figure 1
CONNECTOR
NEST
Figure
3
ADJUSTABLE POST
CONNECTOR

IDT Hand Tool
Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 3 o 6
Revision: A Revision Date: 05-24-13
Figure
5
TOOL
FRAME
REFERENCE MARK
CONNE
CTOR
NEST
OPERATION
Open the hand tool by squeezing the handles together. At the end o the closing stroke, the ratchet mechanism
will release and the handles will spring open.
1. Slide the connector nest out o the tool rame.
2. Place the proper connector into the nest as shown in Figure 4. The mating side o the connector should be
against the top o the nest and the wire holes toward the bottom.
3. Slide the connector nest into the tool rame until the irst termination position is aligned with the re erence mark
on the rame ace. See Figure 5. The connector nest is detented and will “click” into place.
NOTE: I the connector nest is di icult to slide into the tool rame, slide it out and make sure the connector is ully
seated in the nest.
4. Insert the appropriate wire into the connector hole until it stops.
5. Make sure the inserted wire is in alignment with the re erence mark on the rame ace, then squeeze the tool
handles together until the ratchet releases.
NOTE: I the wire is not in alignment with the re erence mark, connector and/or tool damage will occur i
termination is attempted.
NOTE: The ull cycle ratchet action will not release the tool until it has been ully closed.
NOTE: I something jams, the ratchet mechanism can be released by pushing upward on the ratchet pawl
located between the tool handles. See Figure 9.
6. Release the tool handles and allow them to spring open.
7. Move the connector nest to the next termination position. The nest is detented and will “click” into place.
8. Repeat steps 4 through 7 until all terminations are complete.
9. Slide the connector nest out o the tool rame and remove the terminated connector.
Figure 4
ADJUSTABLE POST
CONNECTOR POSITION

IDT Hand Tool
Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 4 o 6
Revision: A Revision Date: 05-24-13
Assembly Inspection
A ter termination, the contacts must be seated to the dimension shown below:
Maintenance
It is recommended that each operator o the tool be made aware o , and responsible or, the ollowing maintenance
steps:
1. Do not use any abrasive materials that could damage the tool.
2. Make certain all pins; pivot points and bearing sur aces are protected with a thin coat o high quality machine
oil. Do not oil excessively. The tool was engineered or durability, it needs cleaning and lubrication or
maximum service li e. Light oil used at the pivot points every 5,000 terminations or 3 months, will signi icantly
enhance the tool li e.
3. Wipe excess oil rom hand tool, particularly rom the terminating area.
4. When tool is not in use, keep the handles closed to prevent objects rom becoming lodged in the termination
punch 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 orce the handles open or
closed. The tool will open easily by pressing the ratchet release lever up. See Figure 9.
Tool Frame Preload
Tool rame preload is not available on this type o rame. The tool should be replaced when it ails to meet
assembly dimensions.
Warranty
This tool is or terminating individual wires into insulation displacement connectors only. All tools are warranted to
be ree o manu acturing de ects or a period o 30 days. Should such a de ect occur, we will repair or exchange
the tool, ree o charge. This repair or exchange will not be applicable to altered, misused, or damaged tools. This
tool is designed or hand use only. Any clamping, ixturing, or use o handle extensions voids this warranty.
CAUTION: Molex speci ications are valid only when used with Molex connectors and tooling.
Series:
93055, 93244, 93395
19 3 +/
-
0 2
19 3 +/
-
0 2
Series:
93065

IDT Hand Tool
Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 5 o 6
Revision: A Revision Date: 05-24-13
CAUTIONS:
1. Manually powered hand tools are intended or low volume, prototyping, or ield repair. This tool is NOT
intended or production use. Repetitive use o this tool should be avoided.
2. Insulated handles are not protection against electrical shock.
3. Wear eye protection at all times.
4. Use only the Molex connectors and wires speci ied or this tool.
Applications for the Modular Crimp Head
WARNING: NEVER operate, service, install, or adjust this Modular Crimp Head without proper instruction and
without irst reading and understanding the instructions in the proper Manual or Speci ication Sheet. See Chart
below or the correct Manual or Speci ication Sheet.
WARNING: NEVER install tooling or service a powered tool while it is connected to any power source.
Disconnect the power source (electric or pneumatic) rom the actuator
CAUTION: Keep ingers away rom the crimping area when operating a powered tool. It can cause severe
injury.
CAUTION: Wear sa ety glasses when operating or servicing this tool.
The chart below shows all applications or this Modular Crimp Head.
Modular Crimp Head
Order No
Tool
Order no Tool Description
Adapter
Order No
Adapter
Description Figure No
63825-9970
63816
-
0000
Hand Crim
p Frame (Short)
N/A
N/A
6
63816
-
0050
Hand Crimp Frame (Long)
N/A
N/A
6
63816
-
0200
Battery Power Tool (110 V)
63816
-
0600
Battery Power Crimp Adapter
7
63816
-
0250
Battery Power Tool (220 V)
63816
-
0600
Battery Power Crimp Adapter
7
63816
-
0100
Air Powe
r Tool
63816
-
0700
Air Power Crimp Adapter
8
Applications for the Modular Crimp Head
Hand 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
AIR
POWER
TOOL
MODULAR
CRIMP HEAD
LOCKING
PINS
LOCKING
PINS
AIR
POWER
CRIMP
ADAPTER
MODULAR
CRIMP
HEAD
BATTERY
POWER
CRIMP
ADAPTER
LOCKING
PINS
LOCKING PINS
BATTERY
POWERED
TOOL

IDT Hand Tool
Doc No: ATS-638259900 Release Date: 05-24-13 UNCONTROLLED COPY Page 6 o 6
Revision: A Revision Date: 05-24-13
RATCHET
RELEASE LEVER
HANDLE
SPRING
2
1
4
Figure 9
3
PARTS LIST
IDT Hand Tool 63825
-
9900
Item
Order No
Description
Quantity
1
63825-9970 Modular Crimp Head 1
2
63816-0000 Hand Crimp Frame (Short) 1
3
63816-0001 Locking Pin 2
4
63600-0525 Handle Spring 1
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