Molex 63825-3000 User manual

Hand Crimp Tool For IllumiMate™ Crimp Terminal

Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 0 -07-12

INSULATION

CRIMP

BRUSH

STRIP

LENGTH

BELL MOUTH

CRI

MP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

Hand Crimp

Tool

Application Toolin

Specification Sheet Order No. 63825-3000

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-620 Class 2 compliant as indicated

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

SCOPE

Products: 1. 0mm (.0 9”) Wire-to-Board IllumiMate™ Receptacle Terminal, 28 AWG.

Terminal

Series No.

Terminal Order No.

Reel Form only

Wire Size

Insulation Diameter

Strip Len th

IPC/WHMA-A620 (1)

Terminal (2)

Insulation Maximum

AWG

mm²

mm In. mm In. mm In.

104 01 104 01-8003 28 0.08

0.8 -0.9

.033-.037

0.9 .037 1.00-1.30

.039-.0 1

Note: This terminal will accommodate UL Style 10368 wire.

(1) To achieve optimum IPC-A620 insulation crimps, use this insulation OD range.

(2) Overall insulation OD specification for terminal.

 Customer to cut off terminal from reel: 0.10mm (.004”) maximum Cut-off Tab.

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 IllumiMate™ Crimp Terminal

Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 0 -07-12

RELEASE

LOCATOR BUTTON

TERMINAL Fi ure 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 Conductor Crimp Insulation Crimp Pull Force

Minimum

Hei ht Width (Ref.)

Hei ht (Ref.)

Width (Ref.)

AWG

mm2

mm In. mm In. mm In. mm In. N Lb.

104 01 28 0.08 0.44-0.48

.017-.019

0.79 .031 1.20 .047 0.93 .037 9.8 2.2

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

occur to the tool or die.





 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.

Note:

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.

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. See Figure 1.

Crimpin Terminals

1. 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.

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Fi ure 2

SQUEEZE

HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Fi ure 1

Hand Crimp Tool For IllumiMate™ Crimp Terminal

Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 0 -07-12

PRE-STRIPPED

WIRE

TERMINAL

Fi ure 5

TERMINAL

WIRE AGAINST

THE WIRE STOP

WIRE

WIRE STOP

IS PART OF

THE LOCATOR

PARTIALLY

CLOSE HANDLE

TOOLING PARTIALLY

CLOSED

Fi ure 4

FIRST RATCHET

POSITION

OPEN

POSITION

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.

. 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 .

7. Crimp the terminal by squeezing the tool handles until the ratchet mechanism

cycle has been completed.

8. Release the handles to open the jaws.

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

9. Remove the crimped terminal from the terminal

locator by pulling on the wire.

10. Visually inspect the crimped terminal for proper

crimp location.

11. 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.

1. 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.

TERMINAL

Fi ure 6

WIRE

WIRE STOP

Hand Crimp Tool For IllumiMate™ Crimp Terminal

Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 0 -07-12

Fi ure 8

PUSH ON

HANDLE

JAWS OPEN

PULL OPEN

TOOLING TOOLING

M3 BHCS

MATCH

UP MARKS

FRONT BACK

Fi ure 9

4. To reinstall the new locator, make sure the hand tool is in the open position.

. 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.

Ri ht 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:

1. 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.

. Reinstall the locator by following the Instructions in the locator replacement section.

Maintenance

It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance

steps:

SQUEEZE

HERE

SQUEEZE

HERE

LOCATOR

Fi ure 7A

TOP HOOKS

TOP SLOTS OF

HANDTOOL

LOWER TABS

MAKE SURE

CENTER OF LOCATOR

IS IN THE

DOWN POSITION

Fi ure 7B

Hand Crimp Tool For IllumiMate™ Crimp Terminal

Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page of 7

Revision: A Revision Date: 0 -07-12

Fi ure 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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 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 ,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.

. 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 Preload (See Fi ure 12)

This hand tool is factory preset to 2 -4 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:

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.

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).

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.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Fi ure 10

RATCHET RELEASE

LEVER

Fi ure 11

Hand Crimp Tool For IllumiMate™ Crimp Terminal

Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 0 -07-12

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.

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

12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than

2 mm (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 IllumiMate™ Crimp Terminal

Doc No: ATS-6382 3000 Release Date: 0 -07-12 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 0 -07-12

RATCHET

RELEASE LEVER

Fi ure 13

PARTS LIST

Item Number Order Number Description Quantity

REF 6382 -3000 Hand Crimp Tool Figure 13

1 6382 -307 Locator Assembly 1

2 63810-0104 Spring, Return 1

3 63810-010 Spring, Ratchet 1

http://www.molex.com

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