Molex 63825-5800 User guide

Tool Kit for CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 1 of 8

Revision: A Revision Date: 08-13-12

INSULATION CRIMP

▲SEE NOTE

USH

STRIP

LENGTH

BELL MOUTH

CRIMP HEIGHT

BEND

DOWN

BEND UP

ROLLING

CONDUCTOR

CRIMP

TWISTING

Application Tooling

Speci ication Sheet

Tool Kit

Order No. 63825-5870

Hand Crimp Tool

Order No. 63825-5800

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.

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

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

SCOPE

Products: CSP 6.3 Receptacle Terminal, 0.35 mm² + 1.00mm², 0.75 mm² + 1.00mm², & (2) 1.00mm² metric wires.

Terminal

Series No.

Terminal

Order No. Wire Size Insulation Diameter Strip Length



Reel Form

Only Wire Style mm² mm In. mm In.

98891 98891-1012

0.35+

1.00

1.25

1.40 +

1.99

2.15

.049

.055 +

.078

.085

5.50 .217

0.75+1.00

0 +

1.90

+.0

IR 1.00+1.00 (2) 1.99-2.15 (2) .078-.085



Customer to cut off terminal from reel: 0.

0mm (.

”) maximum Cut

off Tab.

DEFINITION OF TERMS

TYPE 4C

Tool Kit for CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 2 of 8

Revision: A Revision Date: 08-13-12

▲Insulation Crimp Note:

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. See figure to the right. (Some tools with

multiple crimp pockets may not have the

“overlap” profile on all pockets).

CONDITIONS:

After crimping, the conductor profiles should

measure the following (see notes below).

Terminal Series No.

Bell mouth

Conductor Brush

Bend up Bend Down

Twist Roll

In.

Degree

(Max)

Degree

(Max)

9889

0.40

0.80

015

.030

0.20

.008

Terminal Series No.

Wire Size

Conductor

Crimp

Pro ile

Height

Width

In.

98891

0.35+

1.00

1.83

2.84

.112

0.75+1.00

1.92

1.98

.075

.077

2.78

2.84

.109

.112

1.00+1.00

2.02

2.08

.079

.081

2.78

2.84

.109

.112

Terminal Series No.

Wire Size

Insulation Crimp

Pull Force

Minimum

Height

Width Maximum

In.

Lb.

98891

0.35+1.00

2.55

2.75

.100

.108

4.41

4.61

.174

.181

50.0

11.23

0.75+1.00

2.60

2.80

.102

.110

4.41

4.61

.174

.181

90.0

20.22

1.00+1.00

3.15

3.35

.124

.13

4.41

4.61

.174

.181

120.0

26.96

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, actual crimp height measurements may very slightly. An occasional,

destructive, pull force test should be preformed to check hand tool crimp. Pull Force value must exceed the

minimum pull force specifications listed.

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

can occur to the tool or die.

OVERLAP

INSULATION

CRIMP

OVERLAP FORM GEOMETRY

ANVIL

PUNCH

WIRE

Tool Kit for CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 3 of 8

Revision: A Revision Date: 08-13-12

ANVILS

POWER

CRIMP

HEAD

Figure

PUNCHES

M4 X 10 LONG

BHCS

M4 X 18 LONG

BHCS

SWI

LOCATOR

OPEN

PRESS DOWN

ON THE BRASS

PIVOT SHAFT

LIFT UP ON

THE LOCATOR

Figure

INSTALLATION

To install the Tool Kit into the Power Crimp Head follow the steps below:

Anvils and Punches Installation

1. Insert the Anvils into the bottom slots of the nest. Install the 4 x 10 long BHCS and tighten in place.

2. Insert the Punches into the top slots of the nest. Install the 4 x 18 long BHCS and tighten in place. See

Figure 1.

Locator Installation and Removal

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

To install the locator

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

To remove the 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 Terminals

1. Select the desired terminal listed in the preceding charts.

2. Turn the Locator Lock Latch down to unlock. See Figure 3.

Figure 3

LATCH LOCKED

LATCH UNLOCKED

Tool Kit for CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 4 of 8

Revision: A Revision Date: 08-13-12

Figure 4

SWING OPEN

TERMINAL

PUSH HERE TO

OPEN WIRE STOP LOCATOR

TERMINAL

IN PLACE

Figure 5

WIRE IN TERMINAL

JAWS

PARTIALLY

CLOSED

WIRE AGAINST

WIRE STOP

3. Swing the terminal locator away from the crimp tool shown in Figure 4.

4. Press down on the wire stop on the locator and insert the proper terminal into the proper nest opening. ake

sure when choosing the nest opening, it will correspond with the A, B or C profile on the hand tool.

5. Return the locator to its original position.

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

7. Insert the proper wire over the terminal.

8. Gently touch the end of the wire against the wire stop in the locator. See Figures 5 & 6

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

Release handles to open the jaws.

10. 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.

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

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

For the Battery Power 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.

Figure 6

WIRE

INSULATION

PUNCH

CONDUCTOR ANVIL

LOCATOR

INSULATION

ANVIL

WIRES AGAINST

WIRE STOP

CONDUCTOR

PUNCH

TERMINAL

Tool Kit for CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 5 of 8

Revision: A Revision Date: 08-13-12

Maintenance

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. ake 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. This tool was engineered for durability, but like any fine piece of

equipment, it needs cleaning and lubrication for a maximum service life of trouble-free crimping. 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 7A or 7B for lubrication points.

4. Store the tool in a clean and dry area when not in use.

Miscrimps or Jams or Crimp Hand Tools Only (See Figure 10)

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 10.

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: olex crimp specifications are valid only when used with olex terminals and tooling.

CAUTIONS

1. anually 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 olex terminals specified for crimping with this tool.

CAUTION: Repetitive use of this tool should be avoided.

Certi ication

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

customers to re-certify hand tools.

LUBRICATION

POINTS

(BOTH SIDES)

LIGHT OIL

(EVERY MONTH

5,000 CRIMPS)

Figu

re7A

Figure 7B

Tool Kit for CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 6 of 8

Revision: A Revision Date: 08-13-12

% 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 olex 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

Order No. Tool Order No.

Tool Description

Power

Head

Order No.

Adapter

Description Figure No.

63825-5870

6381

1050

Hand Crimp Frame (Short)

N/A

6381

100

Hand Crimp Frame (Long)

N/A

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 or the Tool Kit

Hand Crimp Tool

Battery Powered Tool

Figure

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 anual or

Specification Sheet. See Chart above for the correct anual or Specification Sheet.

WARNING: NEVER install tooling or service this tool while it is into any power source. ake 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 CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 7 of 8

Revision: A Revision Date: 08-13-12

RATCHET

RELEASE SCREW

Figure 10

M4 X 8mm

LONG BHCS

M4 X 18mm

LONG BHCS

M4 X 10mm

LONG BHCS

WITH TOOL

KIT

LOCATOR ONLY

HAND TOOL PARTS LIST

Item Number

Order Number

Description

Quantity

63810

1000

Hand Crimp Frame (Long)

6382

Tool Kit with

Locator

638

Locator Base

6382

Locator (only)

Tool Kit for CSP 6.3 Receptacle Terminal

Doc No: ATS-6382558H Release Date: 08-13-12 UNCONTROLLED COPY Page 8 of 8

Revision: A Revision Date: 08-13-12

Figure 11

Long

BHCS

Long

BHCS

Long

BHCS

POWER HEAD PARTS LIST

Item

Order No

Engineering No.

Description

Quantity

63816-0300 63816-0300 Power Crimp Head 1

63825-5870 63825-5870 Tool Kit 1

http://www.molex.com

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