Molex 63825-1900 User manual

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12

UNCONTROLLED COPY

Page 1 of 8

Revision A Revision Date 01-24-12

CONDUCTOR

BRUSH

STRIP LENGTH

WIRE SEAL

CONDUCTOR

CRIMP

CUT-OFF

TAB

BELL MOUTH

BEND UP

TWISTING

ROLLING

BEND

DOWN

WIRE

SEAM

Application Tooling

Sp cification Sh t

Tool Kit

Ord r No. 63825-1970

Hand Crimp Tool

Ord r No. 63825-1900

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 63816-0300 Power Crimp Head which is installed

into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.



Many different Tool kits can be used with a single Battery Powered Tool.



This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.

SCOPE

Products 2.80mm (.110")

Sealed Crimp Terminal, Male and Female, 0.50-1.00mm² wire.

T rminal

S ri s No.

T rminal Ord r No. Wir Siz Insulation Diam t r

Strip L ngth

(1) Availabl in R l

form only AWG

mm²

mm in mm in

98012 98012-1102

- 0.50

1.40-2.30

.055-.091

4.7-5.7

.185-.224

- 0.75

- 1.00

98014 98014-0100

- 0.50

- 0.75

- 1.00

(1) Customer to cut off terminal from reel 0.35mm (.014”) maximum Cut-off Tab.

DEFINITION OF TERMS

TYPE 4C

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 2 of 8

Revision A Revision Date 01-24-12

ANVILS

POWER

CRIMP

HEAD

Figur 1

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

CRIMP SPECIFICATION

T rminal S ri s No. B ll Mouth B nd up B nd down Twist Roll Conductor Brush

mm In. D gr D gr mm In.

98012 0.35-0.70 .014-.028 3 3 4 8 0.20-1.00 .008-.039

98014 0.35-0.70 .014-.028 3 3 4 8 0.20-1.00 .008-.039

S am

Seam shall not be open and no wire allowed out of the crimping area

CONDITIONS:

After crimping, the conductor profiles should measure the following (See notes below).

T rminal S ri s No.

Wir Siz Conductor Pull Forc

Minimum Profil

Crimp H ight Crimp Width

AWG

mm2

mm in. mm in. N Lb. A

98012

- 0.50

1.25-1.35

.049-.053

2.05-2.25

.081-.089

75 16.9 X

- 0.75

1.35-1.45

.053-.057

2.05-2.25

.081-.089

90 20.2 X

- 1.00

1.40-1.50

.055-.059

2.09-2.29

.082-.090

120

27.0 X

98014

- 0.50

1.25-1.35

.049-.053

2.05-2.25

.081-.089

75 16.9 X

- 0.75

1.35-1.45

.053-.057

2.05-2.25

.081-.089

90 20.2 X

- 1.00

1.40-1.50

.055-.059

2.09-2.29

.082-.090

120

27.0 X

T rminal

S ri s No.

Singl Wir S al S al Crimp

Crimp H ight Crimp Width

Ord r No. Color mm In. mm In.

98012 ♦024624A Green 3.90-4.10 .154-.161 3.90-4.10 .154-.161

98014

♦This wire seal is a Ford product and not a Molex product. Contact Ford for information on ordering this part.

Tool Qualification Notes

1. Pull Force should be measured with no influence from the insulation crimp.

2. The above specifications are guidelines to an optimum crimp.

CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage

can occur to the tool or die.

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow

the steps below

Anvils and Punch s Installation

1. Insert the Anvils into the bottom slots of the nest.

Install the M4 x 10 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.

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 3 of 8

Revision A Revision Date 01-24-12

SWING

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figur 2

Locator Installation and R moval

Follow the steps below to install or replace the locator. See Figure 2.

To install th locator

1. Position the locator with the hole over the brass pivot shaft and snap it

into place.

To r mov th 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.

Crimping T rminals

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 Figure 4.

5. 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.

6. Return the locator to its

original position.

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

LOCATOR

LOCATOR TERMINAL IN PLACE

Figur 4

Figur 3

LATCH LOCKED

LATCH UNLOCKED

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 4 of 8

Revision A Revision Date 01-24-12

TERMINAL

PRE-STRIPPED

WIRE WITH SEAL

Figur 6

WIRE STOP

BLADE

HANDLE

OPEN

LOCATOR

CLOSED

Figur 5

TERMINAL

PUSH HERE TO

OPEN WIRE STOP

7. Turn the Locator Lock Latch up to lock. Make sure that the terminal is visually centered over the punch.

8. Insert the proper wire with the seal over the terminal.

9. Gently touch the wire stop with the end of the wire. See Figure 6 and 7.

10. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.

Release handles to open the jaws.

11. 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.

12. Visually inspect the crimped terminal for proper crimp location.

Not The tamper proof ratchet action will not release the tool until it has been fully closed.

For th Batt ry Pow r 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.

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.

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. The use of light oil, such as 30 weight automotive oil, every 5,000

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.

Figur 7

WIRE

INSULATION

PUNCH

CONDUCTOR

ANVIL

LOCATOR

INSULATION

ANVIL

WIRES AGAINST

LOCATOR STOP

CONDUCTOR

PUNCH

TERMINAL

WIRE

SEAL

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 5 of 8

Revision A Revision Date 01-24-12

Figur 9

RETRACTOR

SLIDE

Miscrimps or Jams (Crimp Hand Tools Only)

(S Figur 12)

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 12.

Miscrimps or Jams (Batt ry Pow r d Tools)

(S Figur 9)

Should this tool ever become stuck or jammed in a partially closed position, Do Not force the power head

open or closed. The ram can be retracted before the crimping cycle is complete. To do this push the

retractor slide towards the battery. See Figure 9.

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 30

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.

C rtification

Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for

customers to re-certify hand tools.

Figur 8B

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figur 8A

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 6 of 8

Revision A Revision Date 01-24-12

% 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 (1.00”) 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

Ord r No.

Tool

Ord r no.

Tool

D scription

Pow r H ad

Ord r No.

Adapt r

D scription

Figur

No.

63825-1970

63810-1050

Hand Crimp Frame (Short) N/A N/A 10

63810-1000

Hand Crimp Frame (Long) N/A N/A 10

63816-0200

Battery Power Tool (110 V)

63816-0300 Power Crimp Head

63816-0250

Battery Power Tool (220 V)

63816-0300 Power Crimp Head

Applications for th Tool Kit

Hand Crimp Tool Batt ry Pow r d Tool

Figur 10 Figur 11

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

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 7 of 8

Revision A Revision Date 01-24-12

RATCHET

RELEASE SCREW

Figur 12

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

It m Numb r Ord r Numb r D scription Quantity

1 63810-1000 Hand Crimp Frame (Long) 1

2 63825-1970 Tool Kit with Locator 1

3 63825-1975 Locator (only) REF

Tool Kit for 2.80mm (.110") Sealed Crimp Terminal, Male and Female

Doc No ATS-6382519HM Release Date 01-24-12 UNCONTROLLED COPY Page 8 of 8

Revision A Revision Date 01-24-12

Figur 13

M4 by 8 Long

BHCS

M4 by 18 Long

BHCS

M4 by 10 Long

BHCS

POWER HEAD PARTS LIST

It m Ord r No Engin ring No. D scription Quantity

63816-0300 63816-0300 Power Crimp Head 1

63825-1970 63825-1970 Tool Kit with Locator 1

http //www.molex.com

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