Molex 63825-2800 Manuel utilisateur

Hand Crimp Tool For Quick Disconnect, Female Terminals

Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 09-1 -1

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

TERMINAL

STRIP

CONDUCTOR

CRIMP HEIGHT

CUT

OFF

TAB

SEAM

BELL MOUTH

WIRE

HAND CRIMP

TOOL

Application Tooling

Sp cification Sh t Ord r No. 63825-2800

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

 This tool is IPC/WHMA A-6 0 Class compliant as indicated

 This tool is RoHS compliant, however RoHS compliant is not required

SCOPE

Products: Quick Disconnect, Female, for 0.5, 0.8mm² & 1.0mm² and 18- 0 AWG wire,

T rminal S ri s No.

T rminal Ord r No. Wir Siz

Insulation Diam t r

Maximum Strip L ngth

mm²

AWG

In.

94030

40 0

94030

40 1

0.50-1.00

18 - 0

.60 .10 4.5 - 5.5

.177 -. 17

94030

4530

94030

4531

●

Customer to cut off terminal from reel

. Cut tabs flush with terminal at both ends.

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 Quick Disconnect, Female Terminals

Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page of 7

Revision: A Revision Date: 09-1 -1

CONDITIONS:

After crimping, the conductor profiles should measure the following.

T rminal

S ri s No

Wir Siz

Conductor Crimp

▲

Insulation Crimp

Pull Forc

Minimum Profil

H ight Width Maximum

H ight (R f.)

Maximum

Width (R f.)

Maximum

AWG

In.

Lb.

94030

0.5

1.30

–

1.40

.051

.055

.30

.091

3.10

3.5

78.4

17.6

–

.05

.091

3.1

3.5

.138

117.6

6.4

1.0

–

.05

.091

3.5

.138

156.8

35.

Tool Qualification Notes:

1. Pull Force should be measured with no

influence from the insulation crimp.

. The above specifications are guidelines

to an optimum crimp.

▲Insulation Crimp Not :

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 (A6 0 – 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).

OPERATION

CAUTION: Install only Molex terminals listed

above with this tool. Do not crimp hardened

objects as damage can occur to the tool or die.

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 1.

Crimping T rminals

1. Select the desired terminal listed in the

preceding charts.

. 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 .

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figur 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figur 1

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Hand Crimp Tool For Quick Disconnect, Female Terminals

Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 09-1 -1

RELEASE

LOCATOR BUTTON

TERMINAL

Figur 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

PRE

STRIPPED WIRE

TERMINAL

WIRE AGAINST THE

WIRE STOP

Figur 5 TERMINAL

WIRE

WIRE STOP IS PART

OF THE LOCATOR

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.

PARTIALLY

CLOSE HANDLE

TOOLING

PARTIALLY

CLOSED

Figur 4

FIRST RATCHET

POSITION

OPEN

POSITION

Hand Crimp Tool For Quick Disconnect, Female Terminals

Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 09-1 -1

Figur

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING

M3 BHCS

8. Remove the crimped terminal from the terminal

locator by pulling on the wire.

9. Visually inspect the crimped terminal for proper

crimp location.

10. 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.

Not :

A crimp height chart is provided with this manual 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 performed to check hand tool crimp. Pull

Force value Must exceed the Minimum pull force

specifications listed.

Locator R plac m nt

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.

1. Open the crimp hand tool.

. 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 ( ) 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.

TERMINAL

Figur 6

WIRE

WIRE STOP

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Figur 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Figur 7B

Hand Crimp Tool For Quick Disconnect, Female Terminals

Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 09-1 -1

MATCH

UP MARKS

FRONT

BACK

Figur 9

Right or L ft Hand Op ration

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:

1. The locator must be removed before reversing the

tooling.

. 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.

Maint nanc

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.

. 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 11.

How to Adjust Tool Pr load (S Figur 12)

This hand tool is factory preset to 5-45 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:

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figur 10

RATCHET RELEASE

LEVER

Figur 11

Hand Crimp Tool For Quick Disconnect, Female Terminals

Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 09-1 -1

Figur 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

1. Hold the hand tool in the palm of your hand as shown in Figure 10. Using the index finger squeeze the link

towards the top of the hand tool

frame. This will release the preload

adjustment wheel.

. 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).

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:

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.

. 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.

C rtification

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

1 .7mm (1/ ”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than

5mm (1.00”) 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 Quick Disconnect, Female Terminals

Doc No: ATS-638 5 800 Release Date: 09-1 -1 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 09-1 -1

Figur 13

PARTS LIST

It m Numb r

Ord r Numb r

D scription

Quantity

REF

638

Hand Crimp Tool

Figure 13

638

Locator Assembly

63810

0104

Spring, Return

63810

0105

Spring, Ratchet

http://www.molex.com

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