Molex 63825-5500 User guide

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Excellent Integrated System Limited

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Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals

Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 1 of 7

Revision: A Revision Date: 09-05-12

CONDUCTOR

BRUSH

STRIP LENGTH

SEAM

CONDUCTOR

CRIMP HEIGHT

CUT

OFF

TAB

BELL MOUTH

BEND

WISTING

ROLLING

BEND

DOWN

WIRE

INSULATION

CRIMP

HAND CRIMP

TOOL

Application Tooling

Sp cification Sh t Ord r No. 63825-5500

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

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

SCOPE

Products: 1.80mm (.071") PC Board Crimp Terminal, 22-26 AWG.

T rminal S ri s No.

T rminal Ord r No.

Wir Siz and Typ

Insulation Diam t r

(Maximum) Strip L ngth







R l

AWG

mm²

In.

35740

8610

0.35

0.12

1.80

071

2.90

3.40

.114

.134



Customer to cut off terminal from reel: 0.20mm (.008”) maximum Cut

off Tab.

DEFINITION OF TERMS

TYPE 4D

2 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals

Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 2 of 7

Revision: A Revision Date: 09-05-12

▲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 (A620 – compliant). While

the insulation punch profile may appear

“lopsided”, this is a normal condition for this

tool. ee figure to the right. ( ome tools with

multiple crimp pockets may not have the

“overlap” profile on all pockets).

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 (R f.)

Width (R f.)

H ight (R f.)

Width (R f.)

AWG

In.

Lb.

35740

0.35

1.10

1.20

.043

.047

.45

057

2.05

.081

2.1

.083

39.2

8.7

0.20

1.00

1.10

.039

.043

1.45

057

1.85

.073

2.1

.083

29.4

6.5

0.90

1.00

.035

.039

1.45

057

1.80

.071

2.10

.083

19.6

4.4

Tool Qualification Not s:

1. Pull Force should be measured with no

influence from the insulation crimp.

2. The above specifications are guidelines to

an optimum crimp

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 vary 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

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.

ee Figure 1.

MAKE SURE

CENTER OF

LOCATOR

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

LOCATOR

IN DOWN

POSTION

PUSH ON THE

LOCATOR BUTTON

Figur 2

SQUEEZE HANDLES

TOGETHER

HANDLE WILL

SPRING OPEN

Figur 1

3 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals

Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 3 of 7

Revision: A Revision Date: 09-05-12

RELEASE

LOCATOR

BUTTON

TERMINAL

Figur 3

LOCATOR

PUSHED THRU

TOOLING

TERMINAL

LOCATOR

BUTTON

PUSHED IN

LOCATOR

Figur 5

TERMINAL

WIRE AGAINST THE

WIRE STOP

WIRE

WIRE STOP IS PART

OF THE LOCATOR

PRE

STRIPPED WIRE

TERMINAL

Crimping T rminals

1. elect 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. ee 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. ee 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. ee Figure

6. Insert the properly stripped wire through the terminal and against the wire

stop. ee 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

4 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals

Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 4 of 7

Revision: A Revision Date: 09-05-12

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. ee Figure 6.

Locator R plac m nt

ee 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. queeze 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. ee 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.

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.

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

5 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals

Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 5 of 7

Revision: A Revision Date: 09-05-12

MATCH

UP MARKS

FRONT

BACK

Figur 9

2. Remove the M3 BHC which is holding the upper

tooling.

3. Flip the upper tooling to the opposite side and

replace the M3 BHC . 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. ee 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.

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

hould 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. ee Figure

11.

How to Adjust Tool Pr load (S Figur 12)

This hand tool is factory preset to 25-45 LB . 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.

LUBRICATION POINTS

(BOTH SIDES) LIGHT OIL

(EVERY 3 MONTHS OR

5,000 CRIMPS)

Figur 10

RATCHET RELEASE

LEVER

Figur 11

6 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals

Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 6 of 7

Revision: A Revision Date: 09-05-12

Figur 12

SQUEEZE

THE LINK IN

THE HANDLE

HOLD THE HAND

TOOL IN POSITION

SETTING

WHEEL

RATCHET

RELEASE LEVER

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.

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. hould 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.

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

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. ee 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, ( ee 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.

7 / 8

Distributor of Molex Connector Corporation: Excellent Integrated System Limited

Datasheet of 0638255500 - HAND CRIMP TOOL

Hand Crimp Tool for 1.80mm (.071") PC Board Crimp Terminals

Doc No: AT -638255500 Release Date: 09-05-12 UNCONTROLLED COPY Page 7 of 7

Revision: A Revision Date: 09-05-12

Figur 13

PARTS LIST

It m Numb r

d r Numb r

D scription

Quantity

REF

638

Hand Crimp Tool

Figure 13

638

Locator Assembly

63810

0104

pring, Return

63810

0105

pring, Ratchet

Visit our Web site at http://www.molex.com

8 / 8

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